On preventing HAZ cracking in laser welded DS Rene 80 superalloy

Abstract

The heat affected zone (HAZ) cracking behaviour in a laser beam directionally solidified (DS) Rene 80 nickel based superalloy subjected to preweld heat treatments was studied. The HAZ cracks in the alloy are grain boundary liquation cracks caused by liquation reaction of both non-equilibrium secondary solidification product, MC carbides and equilibrium solid state reaction product, γ′ precipitates. In contrast to theoretical prediction based a preweld heat treatment that reduced grain boundary liquid film thickness did not result in a lower HAZ cracking, which can be related to concomitant reduction in the ability of the base alloy to relax welding stress. In addition, formation of intergranular M₅B₃ boride particles in preweld alloy appeared to have aided cracking susceptibility by lowering grain boundary liquation temperature and widening the brittle temperature range in the HAZ during cooling. Based on the analysis of the results, application of a new preweld heat treatment that prevents the formation of the intergranular borides and induces moderate base alloy hardness resulted in a nearly crack free HAZ in laser welded DS Rene 80 superalloy.     

Effect of aluminium concentration in filler alloys on HAZ cracking in TIG welded cast Inconel 738LC superalloy

Abstract

The effect of concentration of aluminium in filler alloys on heat affected zone (HAZ) microfissuring in TIG welded cast Inconel 738LC (IN 738LC) superalloy was studied. Three fillers, IN 625, IN 617 and Haynes 214, with aluminium concentrations varying from 0·2 to 4·5 wt-%, respectively, were used to TIG weld cast IN 738LC alloy plates subjected to two different preweld heat treatments. One preweld heat treatment was the standard solution heat treatment at 1120°C for 2 h followed by argon quenching. The second was a novel overaging treatment developed by the present authors, termed UM treatment, involving solution treatment at 1120°C followed by air cooling and subsequent ageing at 1025°C followed by water quenching. Detailed microstructural analysis of the welds and base metal was done by optical and analytical electron microscopy. Intergranular microfissures were observed in the HAZ of all the welds, irrespective of the filler alloy and the preweld heat treatment, while no cracks were observed in the fusion zone in any of the samples. The cracks were mostly found to be associated with constitutionally liquated MC carbides, borides, sulphocarbides, γ–γ′ eutectic and γ′ precipitates. The cracking was found to increase with increase in the fusion zone hardness and the aluminium content of the fillers, i.e. it was minimum for IN 625 and maximum for Haynes 214, for a particular preweld heat treatment. Between the two heat treatments, the UM treated samples with a smaller base metal hardness, however, exhibited a considerably reduced HAZ cracking. That is, the hardness of the fusion zone as well as the base metal appears to have a significant effect on the cracking susceptibility of the welds made with different fillers.     

Microstructural analysis of fusion and heat affected zones in electron beam welded ALLVAC 718PLUS™ superalloy

The fusion zone and heat affected zone (HAZ) microstructures of electron beam welded superalloy 718PLUS™ (718 Plus) that has been newly developed by ATI ALLVAC were examined. The microsegregation pattern during solidification of the fusion zone indicated that while Fe, Co, W, and Cr segregated to the core of the gamma dendrites, Nb, Ti, and Al were extensively rejected into the interdendritic liquid. Electron diffraction and X-ray microanalysis using transmission electron microscopy (TEM) of the fusion zone showed that the major secondary phases that formed from the interdendritic liquid were gamma/MC type carbide eutectic and gamma/Laves eutectic constituents. HAZ microstructure showed partially melted zone immediately adjacent to the fusion zone and intergranular microfissuring associated with resolidified products which suggested that HAZ cracking in this alloy occurred by liquation cracking. Microstructural examination of the HAZ using analytical scanning electron microscope showed resolidified gamma/Laves eutectic on the cracked and backfilled grain boundaries. Fine resolidified MC type carbide particles were also observed in the HAZ. Causes of grain boundary liquation were identified and the solidification of intergranular liquid in the HAZ was discussed.     

Laser arc hybrid weld microstructure in nickel based IN738 superalloy

Abstract

A study of the microstructural characteristics of laser arc hybrid welded nickel based IN738 superalloy was performed. Laser arc hybrid welding produced a desirable weld profile in the alloy, similar to what is usually obtained during laser beam welding, and no cracking occurred exclusively in the fusion zone. Elemental partitioning pattern in the fusion zone was studied by electron probe microanalysis and calculating the volume fraction of the weld metal that resulted from the consumption of the filler wire. The result showed that Ti, Ta, Nb, Mo, Al and Zr partitioned into the interdendritic regions of the fusion zone. SEM and TEM examination of the fusion zone showed the presence of secondary solidification reaction constituents, which consists of MC type carbides. The study further revealed that non-equilibrium liquation of various second phases that were present in the alloy prior to welding contributed to intergranular liquation in the heat affected zone (HAZ), which consequently resulted in extensive HAZ intergranular cracking during welding. Although laser arc hybrid welding appears promising for improving the weldability of nickel based IN738 superalloy, a suitable weldability improvement procedure is required in order to minimise HAZ intergranular cracking and thereby enhance the applicability of this technology to the joining of the superalloy.     

Characterisation of hot isostatically pressed nickel base superalloy Inconel* 718

Abstract

Inert gas atomised Inconel 718 superalloy powder was characterised for various important properties and subsequently consolidated by hot isostatic pressing (hipping) at 1200° C and 120 MPa for 3 h. The density of the as compacted material was nearly the same as its theoretical density. Optical microscopy of as hipped material showed a fine grained structure with no porosity but having annealing twins and prior particle boundaries (PPBs). Electron probe microanalysis (EPMA) studies revealed that the PPBs were decorated with Al, Ti oxides, and MC type carbides enriched with Nb and Ti. In addition to these phases, the presence of very fine γ"-Ni₃Nb and γ'-Ni₃(Al,Ti) precipitates in the matrix were revealed by TEM analysis, which indicates that the compacted material was partially aged during the slow cooling stage of hipping. Tensile tests conducted on the as hipped material showed that the ultimate tensile strength (UTS) and ductility values were comparable to those obtained in the (solution treated and two step aged) wrought alloy 718, although its yield strength was marginally lower at room temperature.     

In-situ SEM study of temperature-dependent tensile behavior of Inconel 718 superalloy

Journal of Materials Science - The effect of deformation temperature on tensile behavior of Inconel 718 alloy has been studied by a self-developed in-situ high-temperature tensile stage inside a...     

An experimental analysis of effective high speed turning of superalloy Inconel 718

Superalloy, Inconel 718 is widely used in the sophisticated applications due to its unique properties. However, machining of such superior material is difficult and costly due its peculiar characteristics. The present article is an attempt to suggest Taguchi optimization technique to study the machinability of Inconel 718 with respect to cutting force, cutting temperature, and tool life in high speed turning of Inconel 718 using cemented tungsten carbide (K20) cutting tool. Therefore, the objective of this work is divided into two phases: (i) to demonstrate a correlation between cutting speed, feed, and depth of cut with respect to cutting force, cutting temperature, and tool life in a process control of high speed turning of Inconel 718 in order to identify the optimum combination of cutting parameters; (ii) to show the effect of high speed cutting parameters on the tool wear mechanism and chip analysis. These correlations were obtained by multiple linear regressions. The confirmation tests were carried out to make a comparison between the experimental results and mathematical models proposed. The proposed models agree well with the experimental results.     

Micromechanisms of fatigue crack growth in a forged Inconel 718 nickel-based superalloy

The micromechanisms of fatigue crack propagation in a forged, polycrystalline IN 718 nickel-based superalloy are evaluated. Fracture modes under cyclic loading were established by scanning electron microscopy analysis. The results of the fractographic analysis are presented on a fracture mechanism map that shows the dependence of fracture modes on the maximum stress intensity factor, K_max, and the stress intensity factor range, ΔK. Plastic deformation associated with fatigue crack growth was studied using transmission electron microscopy. The effects of ΔK and K_max on the mechanisms of fatigue crack growth in this alloy are discussed within the context of a two-parameter crack growth law. Possible extensions to the Paris law are also proposed for crack growth in the near-threshold and high ΔK regimes.     

Modelling of inertia welding of IN718 superalloy

Abstract

A simple model for the inertia welding of a nickel based superalloy is proposed. The heat flow occurring in the vicinity of the joint is considered, assuming it to be one-dimensional, and this is coupled to a treatment of the stress state expected there using Hill’s general method, so that the upset can be estimated. A state variable constitutive model is included, for the IN718 alloy. It is demonstrated that many of the important characteristics of the process are predicted correctly. It is shown that the shear stress developed at the last stage of the process must be accounted if the upset is to be correctly predicted. The results are compared with those from a 2½D finite element model of the process, and the differences rationalised.     

Microstructural response to heat affected zone cracking of prewelding heat-treated Inconel 939 superalloy

The microstructural response to cracking in the heat-affected zone (HAZ) of a nickel-based IN 939 superalloy after prewelding heat treatments (PWHT) was investigated. The PWHT specimens showed two different microstructures: 1) spherical ordered γ′ precipitates (357–442 nm), with blocky MC and discreet M₂₃C₆ carbides dispersed within the coarse dendrites and in the interdendritic regions; and 2) ordered γ′ precipitates in “ogdoadically” diced cube shapes and coarse MC carbides within the dendrites and in the interdendritic regions. After being tungsten inert gas welded (TIG) applying low heat input, welding speed and using a more ductile filler alloy, specimens with microstructures consisting of spherical γ′ precipitate particles and dispersed discreet MC carbides along the grain boundaries, displayed a considerably improved weldability due to a strong reduction of the intergranular HAZ cracking associated with the liquation microfissuring phenomena.     

Inconel718合金扩散连接接头的组织与性能研究

对细晶Incone1718高温合金无中间层和加Ni箔中间层两种情况下的扩散连接进行了研究,分析了不同的连接温度、连接压力、连接时间等工艺参数对接头剪切强度的影响;通过SEM、EPMA和金相技术对接头微观组织和力学性能进行了分析.确定了获得优质接头的最佳工艺参数区间,即扩散连接温度T=1 050℃,连接压力P=20 MPa,连接时间t=45 min,选用Ni箔作为中间层,厚度为25 μm.     

Fracture toughness analysis of laser-beam-welded superalloys Inconel 718 and 625

In this study, two 3.2‐mm thick Ni‐base superalloys, Inconel 718 and 625, have been laser‐beam‐welded by a 6‐kW CO₂ laser and their room temperature fracture toughness properties have been investigated. Fracture toughness behaviour of the base metal (BM), fusion zone (FZ) and heat affected zone (HAZ) regions was determined in terms of crack tip opening displacement (CTOD) using compact tension‐type (C(T)) specimens. Laser‐beam‐weld regions showed no significant strength overmatching in both alloys. Ductile crack growth analysis (R‐curve) also showed that both materials exhibited similar behaviour. Compared to the BM there is a slight decrease in fracture toughness of the fusion and the HAZ.     

Analysis of laser beam weldability of Inconel 738 superalloy

The susceptibility of pre-weld heat treated laser beam welded IN 738 superalloy to heat affected zone (HAZ) cracking was studied. A pre-weld heat treatment that produced the minimal grain boundary liquation resulted in a higher level of cracking compared to those with more intergranular liquation. This deviation from the general expectation of influence of intergranular liquation extent on HAZ microfissuring is attributable to the reduction in the ability of the base alloy to accommodate welding tensile stress that accompanied a pre-weld heat treatment condition designed to minimize intergranular liquation. Furthermore, in contrast to what has been generally reported in other nickel-based superalloys, a decrease in laser welding speed resulted in increased HAZ cracking in the IN 738, which can be attributed to exacerbated process instability at lower welding speeds.     

A finite element study of thermal relaxation of residual stress in laser shock peened IN718 superalloy

The residual stresses in laser shock peened (LSP) Inconel 718 Ni-base superalloy and their thermal relaxation behavior were investigated based on three-dimensional nonlinear finite element analysis. To account for the nonlinear constitutive behavior, the Johnson-Cook model has been employed and the model parameters for high strain rate response of IN718 are calibrated by comparison with recent experimental results. Based on the LSP simulation, the thermal relaxation behavior was studied through coupled thermal-structure analysis in LS-DYNA. More specifically, the effects of test temperature, exposure time and degree of initial plastic deformation are analyzed and discussed. It is observed that stress relaxation mainly occurs during the initial period of exposure, and the relaxation amplitude increases with the increase of applied temperature and as-peened plastic deformation. Based on the simulation results, an analytical model based on Zener-Wert-Avrami function is proposed to model the thermal residual stress relaxation.     

薄壁GH169合金端接接头焊接缺陷研究

研究了壁厚0．15mmGH169合金端接接头的焊接缺陷产生机理，认为焊接缺陷是焊接过程中焊缝金属被氧化造成的，由于金属被氧化导致了焊缝熔合不良。采用端接接头反面成型及加强背面保护等工艺措施可以极大地降低焊缝熔合不良的敏感性。     

A comprehensive study on surface integrity of nickel-based superalloy Inconel 718 under robotic belt grinding

Surface integrity of materials should be considered under robotic belt grinding in order to achieve desired finishing quality. In this work, the surface integrity of nickel-based superalloy Inconel 718, involving morphological structure, surface roughness, residual stress and structural domain size, was characterized systematically. A novel predicted model of grinding parameters optimization was proposed based on linear weighting function. The result shows that considerable compressive stress (about?355 MPa) and minimum roughness on material surface are achieved simultaneously at the grinding force of 178 kPa and belt speed of 31 m/s. The morphological structures and microhardness for the specimen under the optimized condition were further analyzed and discussed. Surface hardness is increased by 15%. Grain refinement and a large number of dislocations occur in the subsurface, which are attributed to continuous partial dynamic recrystallization associated with combined effects of plastic deformation and thermal treatment, which results from grinding force and belt speed. The new findings are of significance for ensuring surface integrity with optimal process parameters.     

Multisheet structure of Inconel 718 superalloy processed by LBW/SPF technology and its microstructure

Abstract

Multisheet structure of Inconel 718 superalloy will be widely used in vehicles as heat resisting and heat shielding structure due to its lightweight, high strength and stiffness. Multisheet structure of Inconel 718 superalloy was processed by laser beam welding and superplastic forming (LBW/SPF) technology in the present paper. Multisheet structure of Inconel718 superalloy processed by LBW/SPF technology exhibits good configuration and uniform thickness distribution. Laser beam welding parameters for multisheet structure were as follows: pulse frequency was 32 Hz; pulse duration 3 ms; peak power per pulse 4500 W; welding speed 180 mm min^–1; SPF parameters were as follows: temperature T_f=965°C; forming pressure P _f=4·2 MPa; forming time t _f=130 min. Microstructure of multisheet structure was studied carefully. Microstructure in weld fusion zone was constituted of austenite dendritics and Laves phase precipitated in interdendritics. After SPF process, austenite dendritics in the weld fusion became coarser and most of Laves phases were dissolved and turned into δ precipitated phase but a few of Laves phases were still reserved. And Nb concentration in dendritics increased to 5·42% compared to 2·82% under as welded condition. Weld metal hardness increased from 331·63 under as welded condition to 391·74 under post-SPF condition which was closed to the base material hardness of post-SPF. Grain size of base material grew slightly and an amount of precipitated phase appeared in the base material undergoing SPF process. The tensile test results of base material show that tensile strength increased obviously and the ductility decreased slightly after SPF process. Therefore, LBW/SPF technology is an appropriate forming technique for multisheet structure of Inconel 718 superalloy.     

Effect of Grain Size on the Weldability of Cast Alloy 718

Electron beam welding was conducted on cast alloy 718 with varying grain sizes obtained using Microcast (MX™) and conventional cast (CC) techniques. The average value per section of Total Crack Length (Av. TCL) was measured on each cross section and used to represent the material's weldability. It was found for the first time that the grain size had a reduced effect on the weldability of cast alloys, relative to that reported in the literature for wrought alloys; i.e., increased grain size in the range of 90-3000 microns resulted in improved weldability. This was determined to be related to the probability of welds intersecting grain boundaries and causing grain boundary microfissuring. The conclusion from the experimental analysis is corroborated by the use of a Weibull-type analysis to evaluate the probability of a weld microfissure occurring relative to the grain size. As grain size increases, the probability of the weld intersecting the grains is reduced, and thus, the likelihood of microfissuring is reduced. With regard to a single crystal, there are no grain boundaries intercepting the weld (probability = 0), and thus, microfissuring related to constitutional liquation of primary carbides, or segregation of species to grain boundaries would not occur.     

Surface integrity of Inconel 718 by hybrid selective laser melting and milling

ABSTRACT

While selective laser melting (SLM) offers design freedom of metal parts with much less material consumption, there exist several limitations, including high surface roughness, low-dimensional accuracy, and high tensile residual stresses. To make functional parts with high form accuracy and superior surface integrity, an as-SLM part needs finishing to remove the deposited surface material. The integration of machining and SLM creates a hybrid manufacturing route to overcome the inherited limitations of SLM. However, little study has been done to characterise surface integrity of an as-SLM part followed by machining (e.g. hybrid SLM-milling). In this paper, surface, integrity including surface roughness, microstructure, and microhardness, have been characterised for IN718 samples processed by the hybrid process. It has been found that microhardness varies with the scan direction and the use of coolant in the subsequent milling, and surface integrity can be significantly improved by the hybrid SLM-milling route.