Surface integrity in cryogenic machining of nickel based alloy—Inconel 718

In machining processes, a major quality related output is integrity of the machined part surface. In machining of difficult-to-cut materials, a drastic decrease in tool-life makes the machining process even more difficult. By considering the broader perspective of the machining system tailored towards sustainable operations, in this work an alternative—cryogenic machining is evaluated for machining performance. The surface integrity characteristics of machined surface as a function of depth have been analyzed for different combinations of cooling/lubrication machining conditions. The residual stresses on the machined surface and sub-surface, surface hardness, and surface roughness are among the significant characteristics studied in this work. The results show that cryogenic machining processes can be implemented to improve all major surface integrity characteristics, thus improving the final product quality level.     

Investigation of machining performance in high pressure jet assisted turning of Inconel 718: A numerical model

This study aims at investigating the effects of high-pressure jet assistance (HPJA) in rough turning of Inconel 718. A finite element (FE) model for orthogonal machining has been developed in order to reach additional data, compare trends to the experimental ones and understand the influence of the jet on the cutting process. Mechanical and thermal loads induced by the jet are considered. Consequences on the primary and secondary shear zones, chip formation and tool rake face have been studied on a whole pressure range (30-130 MPa) and compared to dry cutting. It is shown that the jet is able to decrease the cutting forces, chip radius and tool-chip contact length. Contact pressure and temperature fields on the cutting tool are also reduced as well as the sticking part of the contact zone. Authors confirmed that the effects of convection are able to change and even amplify the influence of the pure mechanical load induced by the jet.     

Inconel690合金表面处理方法的研究进展

介绍了Inconel 690合金的性质及其应用,重点阐述了表面处理方法,并分析了各种制备技术的优缺点。等离子体渗氮具有其它工艺无法比拟的优势,且经它处理后Inconel 690合金表面耐蚀性、耐磨性明显提高。     

Experimental study on hollow structural component by explosive welding

A large thin-walled hollow structural component with sealed channels is required for the vacuum chamber of a thermonuclear experimental reactor, with inconel625 as its fabrication material. This hollow structural component is rarely manufactured by normal machining method, and its manufacture is also problematic in the field of explosive welding. With this in mind, we developed an adjusted explosive welding technology which involves a two-step design, setting and annealing technology. The joints were evaluated using optical microscope and scanning electron microscope, and a mechanical experiment was conducted, involving micro-hardness test, cold helium leak test and hydraulic pressure test. The results showed that a metallurgical bonding was realized by the ribs and slabs, and the shearing strength of the bonding interface exceeded that of the parent metal. Hence, the hollow structural component has a good comprehensive mechanical performance and sealing property.     

分析右美托咪定静脉泵注在全身麻醉中的应用效果

采用第一性原理计算与实验相结合的方法探究了Cu元素掺杂所造成的元素之间的交互作用对Inconel 718合金Nb偏析的影响。构建了掺杂前后Ni-Fe-Cr-Nb超晶胞模型,计算了掺杂前后各体系的形成热、结合能、态密度、差分电荷密度以及布居分布。计算结果表明,Cu原子的掺杂降低了体系的稳定性;掺杂改变了体系中元素之间的交互作用,影响了原子之间的键合强度及电荷密度分布,Cu的添加增加了基体中Fe原子和Cr原子之间的结合力,但同时也增加了Fe原子和Nb原子之间的排斥力。实验结果表明,微量Cu元素的加入降低了Fe和Cr的偏析,但促进了Nb元素的偏析。第一性原理计算和实验结果表明,Cu掺杂后Nb原子与周围Fe原子间排斥力的增加是Cu促进Nb偏析的本质原因。     

激光熔化沉积WC复合Inconel 718合金微观组织及磨损性能

目的 解决Inconel 718合金在工程应用中存在的磨损失效等问题,探究碳化钨(Tungsten Carbide,WC)对Inconel 718合金磨损性能的增强机理。方法 通过激光熔化沉积技术制备Inconel 718及WC/Inconel 718涂层,通过扫描电镜(Scanning Electron Microscope,SEM) 和X射线衍射(X–ray diffraction,XRD)等测试手段对Inconel 718合金和WC/Inconel 718复合材料的微观组织和物相组成进行观测,探讨其微观组织演变机理;通过硬度测试和摩擦磨损测试对WC复合Inconel 718合金的硬度、摩擦磨损性能及WC复合强化机理进行研究。结果 涂层的微观组织主要由柱状晶、胞状晶和少量等轴晶组成,加入WC后复合材料的晶粒组织比Inconel 718合金的晶粒组织略微细化;Inconel 718合金主要由γ–(Ni, Fe)、γ′–Ni3(Al, Ti)和Fe3Ni2等物相组成,WC/Inconel 718主要由γ–(Ni, Fe)、γ′–Ni3(Al, Ti)、AlCoCrW、CrNi15W和Cr–Ni–Fe–C等物相组成;WC的加入使Inconel 718合金的硬度略有提升,磨损率降至未添加WC时的65.3%,磨损机制以黏着磨损和磨粒磨损为主。结论 WC颗粒在Inconel 718基体中起到了强化硬质颗粒的作用,部分WC颗粒的熔化提高了合金基体的硬度,且生成的高硬度金属化合物与未熔解的球形WC颗粒在Inconel 718合金基体中起到了阻碍晶粒边界运动的钉扎效果,对提升Inconel 718合金的磨损性能有很大帮助。     

准静态加载下时效态Inconel 718薄板的各向异性屈服准则及硬化模型构建

当金属件的特征尺寸缩小到微尺度时,会产生尺寸效应,从而使对微成形的理解变得复杂。本文以0.1mm厚的时效态Inconel 718薄板为研究对象,对其进行了力学性能测试。基于力学测试数据,探究了时效态Inconel 718薄板在相同应变速率、不同拉伸方向上各向异性、延伸率、屈服强度及最大抗拉强度的变化规律,并建立了介微观尺度下各向异性及屈服强度的预测模型和考虑应变量及应变速率的准静态硬化模型。结果表明：时效态Inconel 718薄板具有明显的各向异性,其延伸率以45°为极值点呈现先增大后减小的变化规律,屈服强度和最大抗拉强度的变化规律与之相反。由于尺寸效应的存在需要两组不同的材料参数对各向异性及屈服强度进行预测。当应变速率大于0.1 s_^-1时,材料屈服强度表现出明显的应变速率敏感性,该硬化模型不再适用。     

EXPERIMENTAL INVESTIGATION ON SURFACE INTEGRITY OF END MILLING NICKEL-BASED ALLOY— INCONEL 718

Inconel 718 is a typical difficult-to-machine material, and its high speed end milling process has wide applications in manufacturing parts from aerospace and power industry. Surface integrity of these parts greatly influences the final characteristics. This paper presents an experimental investigation to evaluate surface integrity behaviors in high speed end milling of Inconel 718 with finishing cutting parameters in terms of surface topography, surface roughness Ra, residual stresses, subsurface microstructure, and microhardness. The results show that abraded marks can be observed on the machined surfaces, and high cutting speed is advisable to get better surface topography and roughness quality. Due to high cutting temperature, residual stress is mainly high tensile stress. After increasing the cutting speed beyond 80m/min, the cutting forces hardly increased and the chips take away more cutting heat, which leads to that the residual stress barely increases. Microstructures in subsurface layers have only slight deformations after high speed milling, and there was also no obvious difference when the cutting speed increased beyond 80m/min against the microhardness in subsurface increases together with the cutting speed.     

Size and Shape Effects for Gamma Prime in Alloy 738

Cast IN-738 and wrought Inconel 738 are generic applications for most metallurgical designers of gas turbine blades in the Power Generation Industry on a worldwide basis... Particularly, where first stage buckets are concerned. This is the case because both alloy types exhibit outstanding creep and stress rupture properties to provide an extended service period in a harsh environment. Typically, Alloy 738 is fired in the turbine at 1970 °F (1074 °C) which is about 0.9T _m where T _m represents the melting temperature... A very demanding service temperature, indeed. Furthermore, Alloy 738 is expected to endure this high temperature for a duration of 26,000 h at base load before being retired (R) or replaced (R′) or reused (R′′) issues are ever considered. When these three (3) problems (R-R′-R′′) are brought before a given Materials Review Board for appropriate debate, many pro and con arguments are always evident because (1) Gas turbine blades are not inexpensive and (2) The threat of field failures with possible product liability litigation is of maximum interest to all gas turbine repair shop personnel. The intent of this paper is show how gamma prime precipitate particles can be better examined and more efficiently evaluated using a new characterization method. This research is offered as a contribution to the sum of total knowledge.     

An analytical model to predict specific shear energy in high-speed turning of Inconel 718

Machining of Inconel 718 at higher cutting speeds is expected to provide some relief from the machining difficulties. Therefore, to understand the material behavior at higher cutting speeds, this paper presents an analytical model that predicts specific shearing energy of the work material in shear zone. It considers formation of shear bands that occur at higher cutting speeds during machining, along with the elaborate evaluation of the effect of strain, strain rate, and temperature dependence of the shear flow stress using Johnson–Cook equation. The model also considers the ‘size-effect’ in machining in terms of occurrence of ‘ploughing forces’ during machining. The theoretical results show that the shear band spacing in chip formation increases linearly with an increase in the feedrate and is of the order of 0.2–0.9 mm depending upon the processing conditions. The model shows excellent agreement with the experimental values with an error between 0.5% and 7% for various parametric conditions.