Grain size effect on cyclic deformation behavior and springback prediction of Ni-based superalloy foil

In order to clarify the influence of grain size on cyclic deformation response of superalloy sheets and springback behavior, cyclic loading–unloading and shearing tests were performed on the superalloy foils with 0.2 mm in thickness and diverse grain sizes. The results show that, the decline ratio of elastic modulus is weakened with increasing grain size, and the Bauschinger effect becomes evident with decreasing grain size. Meanwhile, U-bending test results determine that the springback is diminished with increasing grain size. The Chaboche, Anisotropic Nonlinear Kinematic (ANK) and Yoshida-Uemori (Y-U) models were utilized to fit the shear stress–strain curves of specimens. It is found that Y-U model is sufficient of predicting the springback. However, the prediction accuracy is degraded with increasing grain size.     

Hydrogen production enhancement using hot gas cleaning system combined with prepared Ni-based catalyst in biomass gasification

This paper investigates the hot gas temperature effect on enhancing hydrogen generation and minimizing tar yield using zeolite and prepared Ni-based catalysts in rice straw gasification. Results obtained from this work have shown that increasing hot gas temperature and applying catalysts can enhance energy yield efficiency. When zeolite catalyst and hot gas temperature were adjusted from 250 °C to 400 °C, H₂ and CO increased slightly from 7.31% to 14.57%–8.03% and 17.34%, respectively. The tar removal efficiency varies in the 70%–90% range. When the zeolite was replaced with prepared Ni-based catalysts and hot gas cleaning (HGC) operated at 250 °C, H₂ contents were significantly increased from 6.63% to 12.24% resulting in decreasing the hydrocarbon (tar), and methane content. This implied that NiO could promote the water-gas shift reaction and CH₄ reforming reaction. Under other conditions in which the hot gas temperature was 400 °C, deactivated effects on prepared Ni-based catalyst were observed for inhibiting syngas and tar reduction in the HGC system. The prepared Ni-based catalyst worked at 250 °C demonstrate higher stability, catalyst activity, and less coke decomposition in dry reforming. In summary, the optimum catalytic performance in syngas production and tar elimination was achieved when the catalytic temperature was 250 °C in the presence of prepared Ni-based catalysts, producing 5.92 MJ/kg of lower heating value (LHV) and 73.9% tar removal efficiency.     

Multiscale modelling and simulation of single crystal superalloy turbine blade casting during directional solidification process

As the key parts of an aero-engine,single crystal（SX）superalloy turbine blades have been the focus of much attention.However,casting defects often occur during the manufacturing process of the SX turbine blades.Modeling and simulation technology can help to optimize the manufacturing process of SX blades.Multiscale coupled models were proposed and used to simulate the physical phenomena occurring during the directional solidification（DS）process.Coupled with heat transfer（macroscale）and grain growth（meso-scale）,3D dendritic grain growth was calculated to show the competitive grain growth at micro-scale.SX grain selection behavior was studied by the simulation and experiments.The results show that the geometrical structure and technical parameters had strong influences on the grain selection effectiveness.Based on the coupled models,heat transfer,grain growth and microstructure evolution of a complex hollow SX blade were simulated.Both the simulated and experimental results show that the stray grain occurred at the platform of the SX blade when a constant withdrawal rate was used in manufacturing process.In order to avoid the formation of the stray crystal,the multi-scale coupled models and the withdrawal rate optimized technique were applied to the same SX turbine blade.The modeling results indicated that the optimized variable withdrawal rate can achieve SX blade castings with no stray grains,which was also proved by the experiments.     

Effect of long time service exposure on microstructure and mechanical properties of gas turbine vanes made of IN939 alloy

In the present study, the effects of long-term service exposure have been investigated on microstructure and mechanical properties of gas turbine vanes made of IN939 superalloy. The major microstructural changes for the investigated service-exposed vanes include the formation of continuous grain boundary carbides and the transformation (degeneration) of MC carbides located at the grain boundaries. The brittle σ phase, which is predicted to be stable on the basis of thermodynamic calculations, is not observed in the microstructure of service-exposed vanes. The microstructural changes during service lead to a loss in room temperature ductility as well as in creep properties of the alloy.     

铸造镍基高温合金增材修复技术的研究现状

铸造镍基高温合金广泛用于燃气轮机与航空发动机叶片等高温部件,长时间运行过程中经常发生叶片局部损伤失效,其维修或更换成本极高。通过增材修复来恢复局部损伤叶片的性能,将极大地降低制造成本、缩短制造周期、节约资源,具有极大的社会效益和市场价值。本文针对燃气轮机与航空发动机用铸造镍基高温合金部件的服役工况与失效形式,结合铸造镍基高温合金的成分、组织与性能特点,系统分析了增材修复时出现裂纹的类型、特点及形成机理,阐述了各类裂纹的主要影响因素,从增材工艺和材料两方面分类综述了减少或避免裂纹的增材修复工艺与技术现状,分析了不同增材修复方法的优缺点与未来可能的研究热点。     

Room temperature tensile deformation behavior of a Ni-based superalloy with high W content

K416B Ni-based superalloy with high W content has good high temperature properties and low cost, which has a great development potential. To investigate the room temperature tensile property and the deformation feature of K416B superalloy, tensile testing at room temperature was carried out, and optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were used to analyze the deformation and damage mechanisms. Results show that the main room temperature tensile deformation features of the K416B nickel-based superalloy are dislocations slipping in the matrix and shearing into γ′ phase. The <110> super-dislocations shearing into γ′ phase can form the anti-phase boundary two coupled (a/2)<110> partial-dislocations or decompose into the configuration of two (a/3)<112> partial dislocations plus stacking fault. In the later stage of tensile testing, the slip-lines with different orientations are activated in the grain, causing the stress concentration in the regions of block carbide or the porosity, and cracks initiate and propagate along these regions.

     

Effect of strain rate on microstructure evolution of a nickel-based superalloy during hot deformation

The hot deformation behavior of a nickel-based superalloy was investigated by means of isothermal compression tests in the strain rate range of 0.001–10 s⁻¹ at 1110 °C. Transmission electron microscope (TEM) and electron backscatter diffraction (EBSD) technique were used to study the effect of strain rate on the microstructure evolution of the alloy during hot deformation. The results revealed that the dynamic recrystallization (DRX) process was stimulated at high strain rates ($\dot{\epsilon }⩾5{\text{s}}^{-1}$) due to the high dislocation density and adiabatic temperature rise. Meanwhile, high nucleation of DRX and low grain growth led to the fine DRX grains. In the strain rate rage of 0.001–1 s⁻¹, the volume fraction of DRX grains increased with the decreasing strain rate, and the grain growth gradually governed the DRX process. Moreover, the strain rate has an important effect on DDRX and CDRX during hot deformation. On the other hand, particular attention was also paid to the evolution of twin boundaries during hot deformation. It was found that there was a lower fraction of Σ3 boundaries at the intermediate strain rate of 1 s⁻¹, while the fractions of Σ3 boundaries were much higher at both the lower strain rates ($\dot{\epsilon }⩽0.1{\text{s}}^{-1}$) and higher strain rates ($\dot{\epsilon }⩾5{\text{s}}^{-1}$).     

A quantitative metallographic assessment of the evolution of porosity during processing and creep in single crystal Ni‐base super alloys

The present work reviews previous research on the evolution of porosity. It presents new results from a detailed study on the evolution of porosity during casting, heat treatment and creep of a single crystal Ni‐base superalloy subjected to uniaxial tensile creep at 1050 °C and 160 MPa in [001] and [110] directions. A quantitative metallographic study was performed on carefully polished metallographic cross sections, monitoring sampling fields of 4500 × 1000 µm² using the back scatter contrast of an analytical scanning electron microscope; evolutions of pore sizes and pore form factors were analyzed and all important details which were previously revealed in a synchrotron study could be reproduced. In addition, it was observed that micro cracks form at larger cast pores. They interlink and thus initiate final rupture. The [110] tensile creep tests showed lower rupture strains than the [001] experiments. In agreement with earlier work, this can be rationalized on the basis of aligned porosity along primary dendrites.     

一种镍基单晶高温合金中碳化物热稳定性研究

利用SEM、TEM研究了一种镍基单晶高温合金中碳化物在950℃时效不同时间的退化规律。固溶处理过程中形成的MC碳化物随时效时间的增加而逐渐退化为M6 C和M23 C6碳化物。同时,由于在时效处理过程中Re元素进入M6 C碳化物中,破坏了其结构稳定性,促使M6 C碳化物也可以退化为M23 C6碳化物。至时效3000 h时,没有观察到碳化物退化的逆反应。本研究可以为高温合金高温下服役的稳定性提供实验参考。     

航空难加工材料切削刀具磨损与剩余寿命预测研究进展

航空制造领域因轻量化、强度等特殊的应用需求,大量使用钛合金、镍基合金等难切削材料,刀具磨损速率快,刀具过度磨损会影响产品质量,在保证产品质量的前提下,为了充分发挥刀具使用价值,亟需监测刀具磨损状态和预测刀具剩余寿命。针对刀具剩余寿命预测的定义、分类和主要预测方法进行了阐述,同时,刀具磨损监测作为刀具寿命预测的基础和先决条件,简述了其重要的流程和常见模型。刀具剩余寿命预测模型主要包括基于物理模型的预测、基于数据驱动的预测和混合预测三大类,对不同预测方法的优缺点和适用场景进行总结,并讨论了刀具剩余寿命预测的未来研究方向。