Microstructural control in ni-based superalloys for turbine applications: a review of phase-field modeling approaches

Abstract

Nickel-based superalloys are essential materials for high-pressure turbine blades in aero-engines and industrial gas turbines, where their performance is critically determined by the microstructural evolution during solidification and subsequent service. This review presents a comprehensive examination of phase-field modeling approaches applied to microstructural control in single-crystal Ni-based superalloys, with particular emphasis on dendritic solidification, microsegregation, and γ′ precipitate rafting during creep deformation. The theoretical foundations of the phase-field method are discussed, including the Kobayashi formalism for dendritic growth and the KKS multi-component formulation for precipitation phenomena, alongside their coupling with CALPHAD thermodynamic databases for realistic multi-component alloy simulations. Recent advances in integrated simulation workflows linking thermal histories from additive manufacturing process models to phase-field microstructure predictions are critically evaluated, demonstrating the capability to predict primary dendrite arm spacing, solute redistribution patterns, and rafting morphologies with quantitative accuracy validated against experimental measurements. This work addresses computational challenges inherent in multi-scale phase-field simulations and highlights emerging strategies including implicit multigrid schemes and machine-learning-assisted surrogates that enable simulations at industrially relevant length scales.