In-situ μCT 3D visualization on micropores of thin-walled casting using a novel 3rd-generation nickel-based single crystal superalloy under 1100 °C tensile loading

With the advancement of aviation technology, thin-walled structures in superalloys are increasingly adopted in turbine blades for modern aeroengines. However, the mechanical reliability of ultra-thin sections remains a critical challenge. In this study, the high-temperature tensile behavior of thin-walled specimens of a third-generation nickel-based single-crystal superalloy was systematically investigated at 1100 °C. By integrating thin-wall design and in-situ micro-computed tomography imaging, real-time 3D visualization of dendritic structures and micropore evolution during tensile deformation was achieved. The results reveal that micropores progressively aggregate and expand throughout the initial, elastic, plastic and fracture stages. A 13.7 % reduction in tensile strength was observed as the wall thickness decreases from 1.2 mm to 0.3 mm. These findings provide critical insights for optimizing the design and performance of thin-walled turbine blades in advanced aero-engines operating under extreme service conditions.