Cooling γ′ precipitation behavior and strengthening in powder metallurgy su-peralloy FGH4096

Two cooling schemes （continuous cooling and interrupted cooling tests） were applied to investigate the cooling γ precipitation behavior in powder metallurgy superalloy FGH4096. The effect of cooling rate on cooling γ precipitation and the development of γ precipitates during cooling process were involved in this study. The ultimate tensile strength （ErrS） of the specimens in various cooling circumstances was tested. The experiential equations were obtained between the average sizes of secondary and tertiary γ precipitates, the strength, and cooling rate. The results show that they are inversely correlated with the cooling rate as well as the grain boundary changes from serrated to straight, the shape of secondary γ precipitates changes from irregular cuboidal to spherical, while the formed tertiary γ precipitates are always spherical. The interrupted cooling tests show that the average size of secondary γ precipitates increases as a linear function of interrupt temperature for a fixed cooling rate of 24℃/min. The strength first decreases and then increases against interrupt temperature, which is fundamentally caused by the multistage nucleation of γ precipitates during cooling process.

CRITICAL ISSUES OF POWDER METALLURGY TURBINE DISKS

P/M superalloy disks obtain their final strength by appropriate heat treatments; the maximum attainable strength depends on the rapid cooling rate from the solution annealing. A rapid quench of a large disk forging can cause two problems, surface cracking and shape distortion.In the past,many attempts employ the finite element code to model and to predict temperature evolution and induced stress distribution in a large turbine disk. The major difficulty was the correct description of alloy behavior; particularly the thermomechanical properties and the failure criteria of material during the cooling. High temperature fatigue resistance is always the key requirement for disk materials. New methodology of residual life management emphasizes the initiation as well as the propagation of the cracks developed under the service conditions. One of major challenges to P/M superalloys is the time-dependent behavior of fatigue cracking, which relates to the well-known SAGBO (stress-assisted grain boundary oxidation) phenomenon.A great effort has been done to understand the micro-mechanism of time-dependent fatigue crack propagation resulted in the second generation of P/M superalloys. Further improvement on temperature capability of disk alloys at rim area may lead to the idea of dual-property disks.Different grain structures at different portions of a large disk are possible,as the property requirements for different locations are different. This goal is achievable if the thermal history at specific disk locations can be controlled to develop desirable microstructures and properties.Some suggestions on the future direction of research efforts will be discused.

Microstructural evolution in a powder metallurgical Ti-7Mo alloy with continuous oxygen gradient

A titanium alloy containing continuous oxygen gradient was prepared by powder metallurgy(P/M) and the composition–property relationship was studied on a single sample. The alloy was sintered with layered powder of different oxygen contents via vacuum sintering and spark plasma sintering(SPS), respectively. After subsequent heat treatments, high-throughput characterizations of the microstructures and mechanical properties by localized measurements were conducted. The Ti-7% Mo(molar fraction) alloy with an oxygen content ranging from 1.3×10^(-3) to 6.2×10^(-5)(mass fraction) was obtained, and the effects of oxygen on the microstructural evolution and mechanical properties were studied. The results show that SPS is an effective way for fabricating fully dense Ti alloy with a compositional gradient. The average width of α′ phase coarsens with the increase of the content of oxygen. The content of α″ martensitic phase also increases with the content of oxygen. At oxygen contents of 3×10^(-3) and 4×10^(-3)(mass fraction), the Ti alloys present the lowest microhardness and the lowest elastic modulus, respectively. The results also indicate that the martensitic phases actually decrease the hardness of Ti-7Mo alloy, and oxygen effectively hardens the alloy by solid solution strengthening. Therefore, the high-throughput characterization on a microstructure with a gradient content of oxygen is an effective method for rapidly evaluating the composition–property relationship of titanium alloys.

Oxidation during the production of FGH4095 superalloy powders by electrode induction-melt inert gas atomization

Super-clean and super-spherical FGH4095 superalloy powder is produced by the ceramic-free electrode inductionmelt inert gas atomization（EIGA） technique.A continuous and steady-state liquid metal flow is achieved at high-frequency（350 k Hz） alternating current and high electric power（100 k W）.The superalloy is immersed in a high-frequency induction coil,and the liquid metal falling into a supersonic nozzle is atomized by an Ar gas of high kinetic gas energy.Numerical calculations are performed to optimize the structure parameters for the nozzle tip.The undesired oxidation reaction of alloying elements starts at 1000℃ with the reaction originating from the active sites on the powder surfaces,leading to the formation of oxides,MexOy.The role of active sites and kinetic factors associated with the diffusion of oxygen present in the atomization gas streams are also examined.The observed results reveal that the oxidation process occurring at the surface of the produced powders gradually moves toward the core,and that there exists a clear interface between the product layer and the reactant.The present study lays a theoretical foundation for controlling the oxidation of nickel-based superalloy powders from the powder process step.

P/M制备的SiC_p/Al复合材料的界面结构

粉末冶金制备的ＳｉＣｐ／Ａｌ复合材料中，基体与增强体之间存在多种界面类型。除了少数的干净界面、台阶界面外，具有纳米厚度的界面微区在材料中占大多数。进一步研究发现：界面微区是铝多晶体，而且微区中存在镁元素富集，并分布着点状的ＭｇＡｌ２Ｏ４氧化物。

不同粒度的镍基高温合金粉末及其对P/M成形件组织性能影响的研究

研究了用PREP法制造的不同粒度范围的FGH95合金粉末的物理特征及其HIP成形件的组织性能。结果表明 ,使用 5 0～ 10 0 μm和 5 0～ 15 0 μm粒度范围的粉末是降低成本、简化工序、保证产品质量的最佳选择。

P/M制备SiC_p/Al复合材料的研究现状

介绍了粉末冶金制备SiCp/Al复合材料的工艺特点 ,SiCp/Al复合材料和零件的性能 ,粉末冶金制备SiCp/Al复合材料的传统和现行工艺流程 。

美国MPIF《粉末冶金结构零件材料标准(2007年版)》简介

材料的技术标准实际上反映了一个国家或地域的材料产业界的生产管理和技术水平。"粉末冶金结构零件材料标准"自从1984年之后,基本上每3年修订一次。这不仅反映了生产技术的进步,而且也适应了粉末冶金零件在汽车工业中应用的迅速发展。本文重点简介了2007年版标准的改进和淬透性,轴向疲劳及滚动接触疲劳3项技术条件。

CuSn-P-Mo-C系烧结轴承材料性能的研究

采用粉末冶金方法制备了CuSn-P-Mo-C系烧结轴承材料,研究了压坯密度和Mo的加入量对材料性能的影响。结果表明:CuSn-P-Mo-C系烧结轴承材料中,Mo以颗粒状弥散分布在锡青铜基体上,适量的Mo可使材料的压溃强度提高,并具有较低的摩擦系数和磨损量,但随着Mo含量的增加,易产生Mo颗粒团聚,使材料性能下降;Mo含量相同的条件下,压坯密度较低,孔隙集中在试样的中间部位,而压坯密度过高,容易发生供油不足,故其应控制在合理的范围内。本实验条件下,Mo含量为2%,压坯密度在6.50～6.55g/cm3时,CuSn-P-Mo-C系烧结轴承材料性能最佳。

Effect of Processing and Composition on the Structure and Properties of P/M EP741NP Type Alloys

A study was carried out on the effects of processing and composition on the structure and properties of P/M EP741NP type alloys. The objectives of this study were to understand the role of Hf in a P/M superalloy containing high niobium used in aircraft engines and to determine the effects of extrusion and forging the powders as contrasted to HIPing （hot isostatic pressing） only. Two alloys of the P/M EP741NP composition were atomized： one alloy contained 0.26%Hfand the other was Hf free. After the as-atomized powders from both alloys were characterized, the powders were extruded into billets, forged and heat treated. After each process, the microstructures were characterized by SEM and the phases were extracted and identified by X-ray diffraction. The presence of Hf in the residues was probed by EDS （energy dispersive spectroscopy）. The alloys were given the published Russian heat treatment as well as a more conventional heat treatment more typical of western powder alloys. Tensile, creep and stress rupture mechanical property tests were run. Results of the structural behavior of the alloys after each processing step will be presented and discussed. The role of the Hfon the mechanical properties will be discussed.

Effect of Counterface Material on Friction and Wear Behavior of Ni-Cr-W-Al-Ti-MoS_2 Composites

Ni-Cr-W-Al-Ti-MoS2 self-lubricating composites were prepared through the powder metallurgy （P/M） method. Their friction properties were investigated by a pin-on-disk tribometer in the range from the room temperature to 600 ℃. Alumina, silicon nitride and nickel-iron-sulfide alloys were selected as the counterface materials. Results indicate that the lowest friction coefficients under 0.22 can be obtained at 600℃ when rubbed against alumina. When rubbed against nickel-iron-sulfide alloys, are presented the lowest wear rates in the magnitude of 10^-6 mm^3/N-m, one order of magnitude lower than those when rubbed against ceramics. In the case of three rubbing pairs, the wear rates of the composite containing MoS2 present themselves inversely proportional to friction coefficients. With alumina ceramics used as a counterface, transfer films and glaze layers will form on the contact surface playing a main role in lubrication at high temperatures. However, when silicon nitride and nickel-iron-sulfide alloy are used, the lubricating transfer films appear not to be prominent.

SEM in-situ investigation on fatigue cracking behavior of P/M Rene95 alloy with surface inclusions

The low-cycle fatigue behavior of powder metallurgy Rene95 alloy containing surface inclusions was investigated by in-situ observation with scanning electron microscopy （SEM）. The process of fatigue crack initiation and early stage of propagation behavior indicates that fatigue crack mainly occurs at the interface between the inclusion and the matrix. The effect of inclusion on the fatigue crack initiation and the early stage of crack growth was very obvious. The fatigue crack growth path in the matrix is similar to the shape of inclusion made on the basis of fatigue fracture image analysis. The empiric relation between the surface and inside crack growth length, near a surface inclusion, can be expressed. Therefore, the fatigue crack growth rate or life of P/M Rene95 alloy including the inclusions can be evaluated on the basis of the measurable surface crack length parameter. In addition, the effect of two inclusions on the fatigue crack initiation behavior was investigated by the in-situ observation with SEM.

采用氢化-脱氢(HDH)钛粉和氢化钛粉制备MIMTi-6Al-4V合金

以HDH钛粉制备MIMTi-6Al-4V合金的过程为参照,对使用氢化钛粉为原料制备P/M模压钛合金以及MIM钛合金的工艺过程进行了探索。使用HDH钛粉制备的MIMTi-6Al-4V合金抗拉强度为819MPa,拉伸样延伸率为7%;使用氢化钛粉制备的P/M模压Ti-6Al-4V合金拉伸样抗拉性能高于850MPa;使用氢化钛粉为原料制备MIMTi-6Al-4V合金,顺利实现了脱氢-脱脂过程。

粉末冶金法制备SiC_p/6061 Al复合材料的热释放现象

利用机械合金化 粉末冶金制备了SiCp 6 0 6 1Al复合材料。对实验中发现的一种热释放现象进行了计算机在线测量和初步分析。实验表明 ,经机械合金化后制备的SiCp 6 0 6 1Al复合材料中增强体分布均匀 ,在固溶水淬后有明显的热释放现象 ,而且热释放的程度与粉末的尺寸、试样的状态有关。试样在室温自然状态下 ,温度可升高至 80℃左右。

Al-P变质剂制备及其变质效果研究

采用粉末冶金与正挤压相结合的方法制备Al-P变质剂,并对A390过共晶铝硅合金熔体进行变质处理,利用金相和XRD研究Al-P变质处理对组织和初晶硅尺寸的影响。结果表明:Al-P合金坯料在570℃烧结可以制备性能最佳的Al-P变质剂,利用该变质剂在780℃对A390合金进行变质处理时,Al-P变质剂加入合金后迅速溶解,孕育时间极短,组织细化且均匀,初晶硅显著细化,其平均尺寸达到22μm,优于目前已知变质剂的细化效果。

Ni和Fe对Cu-Sn-P系粉末冶金轴承材料性能的影响

在Cu-Sn-P系基体中添加不同量的合金元素N i和Fe,采用粉末冶金方法制备烧结轴承材料,通过对比研究了N i和Fe对其性能的影响规律。结果表明,N i和Fe元素都可以提高材料的表观硬度和压溃强度,改善材料的摩擦磨损性能,但N i元素对压溃强度的提高更为显著。Cu-Sn-P基体中添加N i和Fe含量不宜过高,分别以2%和4%为宜。

ZTA p/Fe45复合材料的强韧性研究

材料的强韧性与材料的耐磨性密切相关。本文研究了氧化锆增韧氧化铝陶瓷颗粒(ZTA p)增强金属基复合材料的强度、韧性以及断裂机理,为改善ZTA p增强金属基复合材料耐磨性提供参考依据。首先通过真空烧结技术制备了不同粒径与不同体积分数的ZTA p/Fe45复合材料,测试了复合材料的拉伸性能、弯曲性能与冲击韧性,采用扫描电镜(SEM)观察了复合材料的断口,分析了复合材料的断裂机制。结果表明:ZTA p的加入使复合材料的强度降低、韧性提高。随着ZTA p体积分数增加,复合材料的抗弯强度逐渐降低;ZTA p粒径增大,复合材料的冲击韧性先增加后降低,ZTA p粒径为2.0 mm与2.5 mm(F14与F12)复合材料的冲击韧性高于Fe45基体。ZTA p/Fe45复合材料的断口为脆性断裂,其中Fe45基体的断裂机理为解理断裂;ZTA p主要有2种失效形式:颗粒断裂和颗粒脱粘拔出。

Influence of Rare Earth on Carbide in Weld Metal

The physical characteristics of Ni based superalloy powder with different particle sizes produced by plasma rotation electrode process (PREP) and the microstructure and mechanical properties of P/M superalloy products were investigated. The experimental results show that the optimum powder particle sizes should be in the range of 50-100 μm or 50-150 μm, which can reduce production cost, simplify process and guarantee P/M product quality.

粉末冶金法制备的P-铁氧体包覆铁粉芯材料

在不采用贵重金属、简化工艺的思路下,采用传统的粉末冶金法结合绝缘涂层包裹高纯度雾化铁粉的工艺制备了不同成分的P-铁氧体包覆铁粉芯软磁复合材料。研究发现,当铁氧体含量0.6 wt%、P含量0.45wt%时,材料的静态软磁性能最好,饱和磁感应强度达1.61 T,矫顽力小于159 A/m且最大磁导率接近4000。从商业化降低成本的角度考虑,以更为廉价的还原铁粉为原料制备了材料并进行了性能对比。结果表明,纯度较低且形状不规则的还原铁粉不适宜用作高性能铁粉芯软磁复合材料的原料。

FGH96合金锻造盘坯热处理过程中的晶粒长大行为

研究了等温锻造后的FGH96合金盘坯件在热处理过程中的晶粒长大规律。结果表明,当热处理温度低于1050℃时,盘坯轮心部位的晶粒几乎不长大;当热处理温度高于1120℃时,轮缘部位晶粒长大迅速;在单相奥氏体区,晶粒的长大规律满足Beck方程,其生长指数随温度升高而增加。当温度一定,初始晶粒越细,其长大速率越快并且生长指数值越高。建立了轮缘部位的晶粒长大动力学方程。