- Research Article
- 10.1016/j.pmatsci.2026.101689
The effect of processing and metallurgical parameters on recrystallization in single crystal nickel-based superalloys – A review
- Mar 01, 2026
- Progress in Materials Science
- Andrew Zang + 6 more +6
Single crystal (SX) nickel-based superalloys represent a critical advancement in the aerospace industry, enabling the manufacture of turbine airfoils capable of withstanding the extreme conditions of modern high-pressure turbine engines. Due to the elimination of grain boundaries, SX airfoils exhibit superior high-temperature properties compared to their polycrystalline counterparts. Consequently, the onset of recrystallization (RX) constitutes the introduction of high angle grain boundaries (HAGBs) into the single crystal lattice, compromising the fatigue and creep performance of the airfoil under operational conditions. RX in SX nickel-based superalloys is primarily driven by the stresses introduced during the investment casting manufacturing process. These stresses create localized regions of strain with associated stored energy within the material, which can trigger the nucleation of RX grains during subsequent solution heat treatment. However, the appearance of RX displays stochastic characteristics, the underlying causes of which are not fully understood. This uncertainty, coupled with the connection between geometry and residual strain evolution, constrains the complexity possible in the geometric features of the airfoil and internal cooling channel, and thus imposes an upper limit on the performance and efficiency gains possible in turbine blade design. Herein, the present review systematically examines the physical fundamentals of RX in SX nickel-based superalloys and provides a critical synthesis of the state of the art in nickel superalloy RX research. Focus is placed on the evolution of microstructure and defects during solidification and subsequent heat treatments, and the interplay between these factors and the spatial distribution of stored energy. From this investigation, the dominant factors affecting the driving force for RX are identified, and potential strategies to mitigate the presence of HAGBs in SX nickel-based superalloy turbine airfoils are proposed
Read more