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Have you spoken with castings technology international they probably have experience in making these complex super alloys.

The cast specification does have aluminium additions. You need to be careful you may clog the filter up if you use these if there is too much slag. You also need to be careful on how much weight you pour through a filter as it can break and leave inclusions in you casting. Deoxidation is key...

Penning Gauge

Graphite flotation does not effect tensile poperties. It can reduce fatigue resistance marginally but i doubt it would cause a failure there maybe other factors that have caused this. If it has then your design criteria is too tight. This should be reviewed and fully investigated and...

In answer to your original question you cannot tell from the unetched pictures what the "dark spots" are. You need to take some high magnification shots and focus in on these features. This way you can interpret whether they are inclusions, dirt on the micro, voids etc. It depends on whether...

This looks like a vacuum melted alloy however it maybe possible depending on the size of the contract to do some development work to manufacture this alloy using special deoxidation techniques and incorporating argon into your process.