EPM-102
About EPM-102 Superalloy
Name and Equivalent Name
EPM-102 is a second-generation nickel-based single-crystal superalloy developed for high-temperature applications. Although no direct equivalent exists, it shares characteristics with alloys like CMSX-4 and PWA 1484, designed for use in aerospace and power generation components.
EPM-102 Basic Introduction
EPM-102 is a nickel-based single-crystal superalloy designed for demanding environments where resistance to creep and fatigue at high temperatures is essential. Its composition ensures mechanical integrity and stability under extreme thermal cycling, making it suitable for turbine blades and engine components.
With high oxidation resistance, EPM-102 can operate reliably at temperatures up to 1050°C, reducing maintenance and extending component life. This alloy is commonly used in jet engines, gas turbines, and other critical applications requiring long-term service in high-temperature environments.
Alternative Superalloys of EPM-102
Alternatives to EPM-102 include second-generation single-crystal alloys such as CMSX-4 and PWA 1484, known for superior creep resistance and fatigue performance. CMSX-2 and SRR 99 are suitable first-generation alternatives, though they may not offer the same level of high-temperature stability. For applications requiring even more excellent thermal performance, third-generation alloys like René N6 may be considered, though at a higher cost.
EPM-102 Design Intention
The design of EPM-102 focuses on enhancing high-temperature creep strength and resistance to thermal fatigue. The alloy's single-crystal structure eliminates grain boundaries, reducing the chances of creep deformation. Cobalt, tungsten, and rhenium in the composition strengthen the matrix and improve long-term stability at elevated temperatures. EPM-102 was developed to meet the growing demand for more durable components in aerospace engines and power turbines, ensuring reliable performance under cyclic thermal loads.
EPM-102 Chemical Composition
The elements in EPM-102 contribute to its exceptional high-temperature performance. Chromium offers oxidation resistance, rhenium and tungsten enhance creep resistance, and aluminum stabilizes the matrix for long-term reliability.
Element | Weight % |
|---|---|
Nickel (Ni) | Balance |
Chromium (Cr) | 6% |
Cobalt (Co) | 9% |
Molybdenum (Mo) | 1% |
Tungsten (W) | 5% |
Aluminum (Al) | 6% |
Tantalum (Ta) | 5% |
Rhenium (Re) | 3% |
EPM-102 Physical Properties
EPM-102 offers excellent mechanical stability, oxidation resistance, and thermal conductivity, making it ideal for extreme environments.
Property | Value |
|---|---|
Density | 8.76 g/cm³ |
Melting Point | 1360°C |
Thermal Conductivity | 10.6 W/(m·K) |
Modulus of Elasticity | 217 GPa |
Tensile Strength | 1100 MPa |
Metallographic Structure of EPM-102 Superalloy
EPM-102’s single-crystal structure eliminates grain boundaries, minimizing creep deformation under stress. The alloy’s gamma (γ) matrix is reinforced with gamma-prime (γ') precipitates, which resist plastic deformation and enhance mechanical stability.
The presence of γ precipitates consisting of nickel, aluminum, and tantalum ensures uniform distribution of stress and improved thermal fatigue resistance. EPM-102’s structure allows it to maintain its mechanical properties even under extreme thermal cycling, making it a preferred choice for aerospace and power generation components.
EPM-102 Mechanical Properties
EPM-102 offers superior creep resistance, excellent tensile strength, and high fatigue resistance, ensuring reliable performance under thermal stress.
Property | Value |
|---|---|
Tensile Strength | ~1200 MPa |
Yield Strength | ~1080 MPa |
Creep Strength | High at 1050°C |
Fatigue Strength | ~650 MPa |
Thermal Fatigue Resistance | Excellent for thermal cycling |
Hardness (HRC) | 42-47 |
Elongation | ~12% |
Modulus of Elasticity | ~230 GPa |
Key Features of EPM-102 Superalloy
High Creep Strength EPM-102 offers outstanding creep resistance at elevated temperatures, making it ideal for turbine blades and critical engine components operating at 1050°C and above.
Thermal Fatigue Resistance EPM -102’s design focuses on withstanding thermal cycling, ensuring durability, and reducing failure risks in components subjected to fluctuating temperatures.
Oxidation Resistance With chromium in its composition, EPM-102 provides robust oxidation resistance, extending the service life of components in harsh environments.
Single-Crystal Structure The absence of grain boundaries enhances fatigue resistance and prevents creep deformation, ensuring long-term stability and mechanical strength.
Long-Term Reliability EPM-102 offers excellent performance for over 20,000 hours at high temperatures, minimizing maintenance and downtime in aerospace and power generation applications.
EPM-102 Superalloy’s Machinability
EPM-102 is compatible with Vacuum Investment Casting because it can form complex, high-precision components with excellent surface quality and minimal porosity.
It is ideally suited for Single Crystal Casting, as it eliminates grain boundaries, enhancing creep resistance and thermal fatigue performance.
EPM-102 is unsuitable for Equiaxed Crystal Casting, as its performance relies on a single-crystal structure that equiaxed grains cannot provide.
While Superalloy Directional Casting is possible, EPM-102 performs better when used as a single-crystal alloy, offering enhanced fatigue life.
It is not recommended for Powder Metallurgy Turbine Disc manufacturing because the single-crystal structure required for optimal performance cannot be achieved through powder metallurgy.
EPM-102 is unsuitable for Superalloy Precision Forging due to difficulties in preserving its microstructure during forging processes.
Superalloy 3D Printing is not feasible, as current additive manufacturing techniques cannot reliably create single-crystal structures.
The alloy can undergo CNC Machining with advanced tooling to achieve precise tolerances, though its hardness requires specialized machining strategies.
Superalloy Welding is challenging for EPM-102 due to potential defects that may compromise its mechanical properties.
Hot Isostatic Pressing (HIP) enhances the performance of EPM-102 by eliminating internal voids and improving its mechanical integrity.
EPM-102 Superalloy Applications
In Aerospace and Aviation, EPM-102 is used in turbine blades and vanes, ensuring excellent fatigue resistance under high-temperature conditions.
For Power Generation, the alloy supports gas turbines, maintaining mechanical integrity under extreme thermal loads and long-term operation.
In Oil and Gas applications, EPM-102 provides reliable performance in high-temperature turbines, ensuring operational efficiency in harsh conditions.
EPM-102 is used in the Energy sector for high-performance turbines, contributing to the efficiency of both conventional and renewable power systems.
In the Marine industry, it enhances propulsion systems and gas turbines, ensuring durability in corrosive environments.
For Mining operations, EPM-102 is utilized in wear-resistant tools and equipment exposed to extreme heat and stress.
In Automotive applications, EPM-102 supports high-performance engines, particularly in motorsports, where thermal fatigue resistance is critical.
Chemical Processing industries benefit from EPM--102’s oxidation resistance, ensuring long service life for reactors and heat exchangers.
In the pharmaceutical and food sectors, the alloy is used in sterilization equipment that requires corrosion resistance and thermal stability.
Military and Defense applications include jet engines and advanced propulsion systems, where EPM-102 offers high strength and fatigue resistance.
In Nuclear applications, EPM-102 ensures the reliability of turbine and reactor components under extreme conditions.
When to Choose EPM-102 Superalloy
EPM-102 should be chosen when exceptional fatigue resistance, high-temperature strength, and long-term stability are essential. This alloy suits custom superalloy parts in jet engines, gas turbines, and high-performance energy systems. It excels in environments requiring resistance to thermal cycling and sustained exposure to extreme temperatures. EPM-102 is particularly valuable in aerospace, power generation, and defense industries, where reliable performance under stress and prolonged service life are critical. When components must endure harsh thermal and mechanical conditions with minimal maintenance, EPM-102 offers the optimal combination of strength, durability, and fatigue resistance.
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