Impact of Co/Ni Ratio on Solidification Characteristics and As-Cast Microstructure of Co-Al-W-Based Superalloys

This study systematically investigated the effects of Co/Ni ratios (0.6–2.0) on the solidification behavior, as-cast microstructure, and element segregation of Co-Al-W-based superalloys, and elucidated the mechanism of thermodynamic and kinetic synergistic regulation. The results show that increasing the Co/Ni ratio has a negligible effect on the liquidus and solidus temperatures, but it significantly lowers the dissolution temperature of the γ′ phase, thereby expanding the alloy’s heat treatment window (HTW) from 215 °C to 269 °C. As the Co/Ni ratio increased from 0.6 to 2, the SDAS at the center of the alloy ingot decreased from 112.4 μm to 43.3 μm, resulting in a significant refinement of the as-cast microstructure. The dendritic segregation coefficients for positively segregating elements such as Ta, Hf, and Al, as well as negatively segregating elements such as W, all approached 1 significantly, effectively suppressing microsegregation during solidification. This study reveals the multidimensional synergistic regulation mechanism of the Co/Ni ratio on the non-equilibrium solidification behavior of highly alloyed Co-Al-W-based superalloys and quantitatively elucidates the relationship between the Co/Ni ratio, the microstructural uniformity of as-cast specimens, and the heat treatment process window. For the first time in a highly alloyed multi-component Co-Al-W system, a correlation has been established between the Co/Ni ratio, element segregation, dendrite coarsening coefficient, and heat treatment window.