On the origin of superlattice stacking faults nucleation via climb of Frank partial in CoNi-based superalloys

Abstract

High-temperature deformation in superalloys is governed by the cooperative glide-climb motion of dislocations. Superlattice stacking faults (SFs) in the gamma prime phase are predominantly interpreted as nucleating via conservative Shockley partial glide. Here, we demonstrate that non-conservative climb of a/3<111> Frank partials constitutes a general and kinetically viable pathway for both superlattice intrinsic (SISFs) and extrinsic stacking faults (SESFs) formation in the L12 structure of CoNi-based superalloys during compression at 850 Celsius. High-resolution transmission electron microscopy reveals that Frank partials form at gamma/gamma prime interface can climb into the gamma prime phase, generating SISFs via positive climb and SESFs via negative climb. Importantly, the negative climb-assisted nucleation of SESFs is experimentally confirmed for the first time, and the observed positive climb-assisted SISF configuration differs fundamentally from previously reported mechanisms. We show that these Frank partials originate from the reaction between a leading 30 degree Shockley partial and a 60 degree mixed dislocation on conjugate {111} planes, producing energetically stable configurations that promote subsequent climb. Energetic and kinetic analyses demonstrate that solute segregation induced reduction of SF energy provides a dominant contribution to Frank partial climb, enabling sustained climb and consequent SF expansion. Quantitative comparisons further indicate that, at elevated temperatures, solute drag-controlled Shockley glide can achieve mobilities comparable to vacancy diffusion-controlled Frank climb. These findings establish climb-assisted SF formation as a unified deformation mechanism in gamma prime phase, and that both SISF and SESF expansion can proceed through Frank partial climb.