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Nickel-based super alloys have been widely used as high temperature structural materials in gas turbine engine applications owing to their excellent high temperature rupture life, corrosion and oxidation resistance. The increasing trend of higher operating temperatures and pressure ratios in aero engines require nickel-based super alloys with even higher alloying content to give increased levels of creep resistance, greater low cycle fatigue resistance, with micro structural stability and damage tolerance at the elevated temperatures.However due to the complex chemistry and high alloying content of these super alloys, macro segregation and coarse grain size occurs in the convectional cast and wrought processes . A powder metallurgy (PM) route can eliminate macro segregation since the biggest amount of segregation in the parts produced by PM methods is limited by particle size.In addition, by using PM methods micro structural control can be enhanced and thus component performance can be improved. Also, complex net-shaped components can be produced by some PM technologies , such as hot isostatic pressing , metal injection moulding, additive layer manufacturing and laser deposition manufacturing.
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