Phase constitution,microstructure and mechanical properties of a Ni-based superalloy specially designed for additive manufacturing

In this study, a kind of Ni-based superalloy specially designed for additive manufacturing (AM) was investigated. Thermo-Calc simulation and differential scanning calorimetry (DSC) analysis were used to determine phases and their transformation temperature. Experimental specimens were prepared by laser metal deposition (LMD) and traditional casting method. Microstructure, phase constitution and mechanical properties of the alloy were characterized by scanning electron microscopy (SEM), transmission scanning electron microscopy (TEM), X-ray diffraction (XRD) and tensile tests. The results show that this alloy contains two basic phases, γ/γ', in addition to these phases, at least two secondary phases may be present, such as MC carbides and Laves phases. Furthermore, the as-deposited alloy has finer dendrite, its mean primary dendrite arm space (PDAS) is about 30-45 μm, and the average size of γ' particles is 100-150 nm. However, the dendrite size of the as-cast alloy is much larger and its PDAS is 300-500 μm with secondary and even third dendrite arms. Correspondingly, the alloy displays different tensile behavior with different processing methods, and the as-deposited specimen shows better ultimate tensile stress (1,085.7±51.7 MPa), yield stress (697±19.5 MPa) and elongation (25.8%±2.2%) than that of the as-cast specimen. The differences in mechanical properties of the alloy are due to the different morphology and size of dendrites, γ', and Laves phase, and the segregation of elements, etc. Such important information would be helpful for alloy application as well as new alloy development.     

Methods and mechanisms for uniformly refining deformed mixed and coarse grains inside a solution-treated Ni-based superalloy by two-stage heat treatment

The uniform refinement mechanisms and methods of deformed mixed and coarse grains inside a solution-treatment Ni-based superalloy during two-stage annealing treatment have been investigated.The two-stage heat treatment experiments include an aging annealing treatment(AT)and a subsequent recrystallization annealing treatment(RT).The object of AT is to precipitate some δ phases and consume part of storage energy to inhibit the grain growth during RT,while the RT is to refine mixed and coarse grains by recrystallization.It can be found that the recrystallization grains will quickly grow up to a large size when the AT time is too low or the RT temperature is too high,while the deformed coarse grains cannot be eliminated when the AT time is too long or the RT temperature is too low.In addition,the mixed microstructure composed of some abnormal coarse recrystallization grains(ACRGs)and a large number of fine grains can be observed in the annealed specimen when the AT time is 3 h and RT tem-perature is 980℃.The phenomenon attributes to the uneven distribution of δ phase resulted from the heterogeneous deformation energy when the AT time is too short.In the regions with a large number of δ phases,the recrystallization nucleation rate is promoted and the growth of grains is limited,which results in fine grains.However,in the regions with few δ phases,the recrystallization grains around grain boundaries can easily grow up,and the new recrystallization nucleus is difficult to form inside grain,which leads to ACRGs.Thus,in order to obtain uniform and fine annealed microstructure,it is a prereq-uisite to precipitate even-distributed δ phase by choosing a suitable AT time,such as 12 h.Moreover,a relative high RT temperature is also needed to promote the recrystallization nucleation around δ phase.The optimal annealing parameters range for uniformly refining mixed crystal can be summarized as:900℃×12 h+990℃×(40-60 min)and 900℃×12 h+1000℃×(10-15 min).     

镍基高温合金GH202高温氧化后的微观组织演变

研究了镍基高温合金GH202在800~1100 ℃高温氧化后晶粒、碳化物和强化相的演变过程。采用透射电子显微镜、扫描电子显微镜和电子背散射衍射对其微观结构进行了表征。结果表明：镍基高温合金的硬度随氧化温度的升高而降低，1100 ℃氧化100 h后，硬度降低了43.5%。800和900 ℃氧化后晶粒生长速度较慢，而经900 ℃氧化后晶界碳化物析出显著增加。在1000和1100 ℃氧化后，晶粒尺寸明显增大。氧化过程中晶界迁移是由晶界两侧自由能差决定，温度越高，晶界向曲率中心迁移越快，大量细小晶粒被吞并形成了大晶粒。大块状碳化物（MC）分解成大量的碳原子，与Cr原子结合形成少量的富Cr颗粒状M₂₃C₆。在900 ℃氧化150 h后，M₂₃C₆演化为富Ti的M₆C。随着氧化温度的升高，碳化物在γ相中回熔。在800、900和1000 ℃氧化后，γ′相逐渐长大，在1100 ℃氧化100 h后，完全溶解于γ相。     

Effect of metallurgical evolution during post-weld aging treatment on localised corrosion of resistance spot welding joints of A286 superalloy

The combined effect of resistance spot welding and precipitation hardening on the localised corrosion of A286 superalloy is studied. The specimens tested by double loop electrochemical potentiokinetic reactivation were welded in the solution treated condition, and then subjected to different precipitation hardening treatments. For both base metal and weld nugget, the maximum localised corrosion is reached when η phase is clearly observable. The fact that the localised corrosion resistance of weld nugget is different from that shown by base metal may be explained by the segregation of Ni and Ti towards the interdendritic region of weld nugget (studied by using scanning electron microscope/energy dispersive X-ray analysis).     

Wear and Tribological Performance of Different Ceramic Tools in Dry High Speed Machining of Ni-Co-Cr Precipitation Hardenable Aerospace Superalloy

Tool wear is an important machinability criterion. To reduce total machining costs, this study demonstrates the wear and tribological performance of four ceramic tools in dry high-speed turning of Ni-Co-Cr precipitation hardenable superalloy (Inconel 100). Wear of the tool materials and the structural and phase transformations at the tool–chip interface were investigated. Results obtained reveal that SiAlON ceramic outperformed other ceramic tool materials at different cutting speeds due to the formation of a large amount of mullite tribofilms on the tool face, which serve as a thermal barrier layer. Alumina ceramic with the addition of ZrO₂ can be recommended for machining Inconel 100 at speeds above 150 m/min due to its ability to form thermal barrier ZrO₂ tribofilms, which decrease the coefficient of friction at the tool–chip interface. Mixed alumina and an alumina matrix reinforced with SiC_w were found to be unsuitable for machining age-hardened Inconel 100 superalloy.     

New insights into microstructural changes during transient liquid phase bonding of GTD-111 superalloy

The effects of joining temperature (T_J) and time (t_J) on microstructure of the transient liquid phase (TLP) bonding of GTD-111 superalloy were investigated. The bonding process was applied using BNi-3 filler at temperatures of 1080, 1120, and 1160 °C for isothermal solidification time of 195, 135, and 90 min, respectively. Homogenization heat treatment was also applied to all of the joints. The results show that intermetallic and eutectic compounds such as Ni-rich borides, Ni−B−Si ternary compound and eutectic-γ continuously are formed in the joint region during cooling. By increasing t_J, intermetallic phases are firstly reduced and eventually eliminated and isothermal solidification is completed as well. With the increase of the holding time at all of the three bonding temperatures, the thickness of the athermally solidified zone (ASZ) and the volume fraction of precipitates in the bonding area decrease and the width of the diffusion affected zone (DAZ) increases. Similar results are also obtained by increasing T_J from 1080 to 1160 °C at t_J=90 min. Furthermore, increasing the T_J from 1080 to 1160 °C leads to the faster elimination of intermetallic phases from the ASZ. However, these phases are again observed in the joint region at 1180 °C. It is observed that by increasing the bonding temperature, the bonding width and the rate of dissolution of the base metal increase. Based on these results, increasing the homogenization time from 180 to 300 min leads to the elimination of boride precipitates in the DAZ and a high uniformity of the concentration of alloying elements in the joint region and the base metal.     

镍基高温合金锥筒形件拉深旋压成形机理研究

针对镍基高温合金因加工硬化严重成形时极易产生破裂和起皱等典型缺陷的问题,以锥筒形壳体类零件为对象,提出了一种由锥形预制坯经过真空固溶处理后拉深旋压成形锥筒形件的方法,并对其成形机理进行了研究。基于Abaqus/Explicit平台,建立了锥筒形件拉深旋压有限元模型,分析了成形过程中的瞬态等效应力、等效塑性应变、切向应力、壁厚及三向应变分布规律。结果表明:在旋压成形过程中,最大瞬态等效应力位于旋轮接触区及附近区域、最大瞬态等效塑性应变位于坯料口部;瞬态切向压应力最大值位于旋轮接触区,而瞬态切向拉应力最大值位于旋轮接触区附近的两侧区域。筒形段中部壁厚减薄,而坯料口部壁厚增厚。旋压成形试验表明,锥形预制坯经拉深旋压后可获得壁厚均匀的锥筒形件。     

高温合金蜂窝成形制造工艺及性能评价

目的 研究高温合金蜂窝成形工艺参数优化规律。方法 采用辊压成形、整形和点焊工艺制备高温合金蜂窝芯体，并对成形后的蜂窝芯体进行性能表征及失效分析。研究辊压成形工艺、整形工艺和点焊工艺参数，对采用最优工艺参数得到的高温合金蜂窝芯体样件分别进行压缩、剪切性能测试，对样件进行性能表征及失效分析，得出其最大压缩力、平面压缩强度以及失效方式。结果 选取30 t压力时，校形效果良好；当焊接电流为500 A，焊接时间为0.005 s时，焊点质量最好。结论 采用优化后的工艺参数制得的样件尺寸精度和质量较高，能够为高温合金蜂窝制造提供指导。     

热等静压处理对K439B高温合金显微组织的影响

对K439B合金进行了1165 ℃/150 MPa,4 h热等静压处理,采用光学显微镜和扫描电镜对比研究了铸态和热等静压态K439B合金的显微组织。结果表明:铸态K439B合金存在0.25%的显微疏松,热等静压后显微疏松基本消除(0.013%)。与铸态相比,经过热等静压处理后合金中的γ/γ′共晶组织体积分数和尺寸减小,各元素分布更加均匀,凝固偏析系数均更接近1。铸态K439B合金枝晶干处γ′相尺寸和体积分数分别是116.9 nm和17.8%,枝晶间部位γ′相尺寸和体积分数分别为244.4 nm和24.9%。热等静压后合金枝晶干部位的γ′相尺寸及体积分数分别为148.0 nm和17.5%,枝晶间部位γ′相尺寸和体积分数分别为159.1 nm和22.8%。热等静压处理使合金枝晶干、枝晶间部位的γ′相尺寸、体积分数和形貌接近,同时γ′相分布变得均匀。