This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting(SLM)followed by high-speed milling(HSM).In the investigation process of surface integrity,the study emp...This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting(SLM)followed by high-speed milling(HSM).In the investigation process of surface integrity,the study employs ultradepth three-dimensional microscopy,laser scanning confocal microscopy,scanning electron microscopy,electron backscatter diffractometry,and energy dispersive spectroscopy to characterize the evolution of material microstructure,work hardening,residual stress coupling,and anisotropic effect of the building direction on surface integrity of the samples.The results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic layer.High-speed machining is adopted to reduce cutting force and suppress machining heat,which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing process.In general,high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity,compared to simplex additive manufacturing or casting.展开更多
New materials and manufacturing technologies require applicable non-destructive techniques for quality assurance so as to achieve better performance.This study comprehensively investigated the effect of influencing fa...New materials and manufacturing technologies require applicable non-destructive techniques for quality assurance so as to achieve better performance.This study comprehensively investigated the effect of influencing factors includ-ing excitation frequency,lift-off distance,defect depth and size,residual heat,and surface roughness on the defect EC signals of an Inconel 738LC alloy produced by selective laser melting(SLM).The experimental investigations recorded the impedance amplitude and phase angle of EC signals for each defect to explore the feasibility of detecting sub-surface defects by merely analyzing these two key indicators.Overall,this study revealed preliminary qualitative and roughly quantitative relationships between influencing factors and corresponding EC signals,which provided a prac-tical reference on how to quantitively inspect subsurface defects using eddy current testing(ECT)on SLMed parts,and also made solid progress toward on-line ECT in additive/subtractive hybrid manufacturing(ASHM)for fabricating SLMed parts with enhanced quality and better performance.展开更多
The influence of casting parameters on stray grain formation of a unidirectionally solidified superalloy IN738LC casting with three platforms was investigated by using a 3D cellular automaton-finite element(CAFE) mode...The influence of casting parameters on stray grain formation of a unidirectionally solidified superalloy IN738LC casting with three platforms was investigated by using a 3D cellular automaton-finite element(CAFE) model in CALCOSOFT package.The model was first validated by comparison of the reported grain structure of Al-7%Si(mass fraction) alloy.Then,the influence of pouring temperature,heat flux of the lateral surface,convection heat coefficient of the cooled chill and mean undercooling of the bulk nucleation on the stray grain formation was studied during the unidirectional solidification.The predictions show that the stray grain formation is obviously sensitive to the pouring temperature,heat flux and mean undercooling of the bulk nucleation.However,increasing the heat convection coefficient has little influence on the stray grain formation.展开更多
Up to now, the aluminide coatings used to protect industrial components at high temperature and corrosive environments have been modified by Pt, Cr, Si and Ni. In this investigation, aluminide coatings were modified b...Up to now, the aluminide coatings used to protect industrial components at high temperature and corrosive environments have been modified by Pt, Cr, Si and Ni. In this investigation, aluminide coatings were modified by titanium and the microstructural feature and formation mechanism were evaluated. The coatings were formed on a Ni-based superalloy(IN738LC) by a two stage process including titanizing at first and aluminizing thereafter. Pack cementation titanizing performed at temperatures 950° C and 1050° C in several mixtures of Ti, A12O3 and NH^Cl. At the second stage, aluminum diffused into surface of the specimens by an industrial aluminizing process known as Elcoatl01(4 hrs at 1050° C). The modified coatings were characterized by means of standard optical microscopy, scanning electron microscopy, energy dispersive spectroscopy and X-Ray diffraction methods. The results show that Ti in the coatings is mainly present in the form of TiNi and Al67Cr8Ti25. Titanium modified coatings grew with a mechanism similar to simple aluminizing; this includes inward diffusion of Al from the pack to the substrate and then outward diffusion of Ni from the substrate to the coating. The advantages and characteristics of this two-stage modified coating is discussed and the process parameters are proposed to obtain a coating of optimum microstructure.展开更多
In this investigation, aluminide coatings used to protect industrial components at high temperature and corrosive environments were modified with silicon addition and the microstructural features and formation mechani...In this investigation, aluminide coatings used to protect industrial components at high temperature and corrosive environments were modified with silicon addition and the microstructural features and formation mechanism were evaluated. The coating on the nickel-based superalloy IN738LC was carried out by a two stage process including siliconizing at first and aluminizing thereafter. Pack cementation siliconizing performed at 950C for 2, 4 and 6 hours in several powder mixtures of Si, A12O3 and NHiCl, then aluminum was diffused into the surface of the specimens by an industrial aluminizing process. The modified coatings were characterized by means of standard metallography, scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction methods. The results show that Si in the coatings mainly presents in the form of secondary phases including Cr3Si, Mo5Si3 and Nii6Ti6Si7, well distributed within the NiAl matrix. The advantages of this two stage modified coating is discussed.展开更多
Transient liquid phase（TLP） bonding of IN738 LC superalloy was carried out using a rapidly solidified MBF-15 Ni-based foil. The effects of bonding temperature（1130–1170 °C） and time（5–120 min） as well as ...Transient liquid phase（TLP） bonding of IN738 LC superalloy was carried out using a rapidly solidified MBF-15 Ni-based foil. The effects of bonding temperature（1130–1170 °C） and time（5–120 min） as well as foil thickness（35–140 μm） were studied on the microstructure of joint region and its mechanical properties. The solidification sequence in the joint region was found to be（i） formation of γ solid solution in the isothermally solidified zone, followed by（ii） ternary eutectic of γ ＋ Ni3 B ＋ Cr B, and finally（iii） binary eutectic of γ ＋ Ni3 Si in the athermally solidified zone. Fine Ni3 Si particles were also formed via a solid state transformation within the γ matrix in the vicinity of eutectic products. A deviation of isothermal solidification kinetics from the standard parabolic TLP model was observed by increasing the bonding temperature to 1170 °C, which resulted in the formation of eutectic constituents at the joint centerline.The analysis of mechanical and fractographic test results revealed that the samples with complete isothermal solidification exhibit the highest shear strength, whereas the hard eutectic constituents act as preferential failure sites and lead to a significant reduction in the joint shear strength in samples with incomplete isothermal solidification.展开更多
The present study investigated the effect of as-built and post heat-treated microstructures of IN738LC alloy fabricated via selective laser melting process on high temperature oxidation behavior.The as-built microstru...The present study investigated the effect of as-built and post heat-treated microstructures of IN738LC alloy fabricated via selective laser melting process on high temperature oxidation behavior.The as-built microstructure showed fine cell and columnar structure due to high cooling rate.Ti element segregation was observed in inter-cell/inter-columnar area.After post heat-treatment,the initially-observed cell structure disappeared,instead bimodal Ni_3(Al,Ti)particles formed.High temperature(1273 K and 1373 K)oxidation test results showed parabolic oxidation curves regardless of temperature and initial microstructure.The as-built IN738LC fabricated via the selective laser melting process displayed oxidation resistance similar to or slightly better than that of IN738LC fabricated via wrought or cast process.Heat-treated SLM IN738LC,although had similar oxidation weight-gain values to those of the SLM asbuilt material at 1273K,showed relatively better oxidation resistance at 1373 K.Bimodal Ni_3(Al,Ti)precipitate formed in the post heat treatment changed the local chemical composition,thereby led to changes in alumina former/chromia former location and fraction on the alloy surface.It was concluded that in heat-treated IN738LC increased alumina former fraction was found,and this resulted in excellent oxidation resistance and relatively low weight-gain.展开更多
Nickel-based superalloy IN738LC produced by selective laser melting(SLM)exhibits inferior hightemperature creep properties than its cast counterparts due to relatively smaller grain size,particularly for the plane nor...Nickel-based superalloy IN738LC produced by selective laser melting(SLM)exhibits inferior hightemperature creep properties than its cast counterparts due to relatively smaller grain size,particularly for the plane normal to the building direction.This work studied effects of post heating strategy on the microstructure and especially the grain size to improve the high temperature creep resistance.The asbuilt microstructure exhibited a fine grain size and large quantities of MC carbides that could effectively hinder grain growth.It was found that unconventional two-step heat treatments could lead to substantial grain growth,and the effect is particularly prominent at a specific temperature.The ease of grain growth was explained after classifying the microstructural evolution(boundary carbide transformation)during each heating step and related to the reduced grain boundary pinning force from MC carbides.Creep tests validated the effect of the new heat treatment scheme on the SLM-processed IN738LC at 850℃.An extended creep fracture life(1.5 to 4 times improvement)and lower secondary creep rates were achieved with samples subjected to the newly optimized two-step heat treatment.The complete creep curves are also firstly presented for SLM-IN738LC,confirming the effectiveness of grain growth and highlighting the importance of dedicated heat treatment for SLM superalloys.展开更多
基金Shenzhen Municipal Science and Technology Innovation Commission Projects(Grant Nos.Y01336107,JCYJ20180504165824643,GJHZ20180411143506667,JC YJ20170817111811303 and KQTD20190929172505711)。
文摘This study is concerned with the surface integrity of Inconel 738LC parts manufactured by selective laser melting(SLM)followed by high-speed milling(HSM).In the investigation process of surface integrity,the study employs ultradepth three-dimensional microscopy,laser scanning confocal microscopy,scanning electron microscopy,electron backscatter diffractometry,and energy dispersive spectroscopy to characterize the evolution of material microstructure,work hardening,residual stress coupling,and anisotropic effect of the building direction on surface integrity of the samples.The results show that SLM/HSM hybrid manufacturing can be an effective method to obtain better surface quality with a thinner machining metamorphic layer.High-speed machining is adopted to reduce cutting force and suppress machining heat,which is an effective way to produce better surface mechanical properties during the SLM/HSM hybrid manufacturing process.In general,high-speed milling of the SLM-built Inconel 738LC samples offers better surface integrity,compared to simplex additive manufacturing or casting.
基金the financial supports from the Major Project of Science and Technology of Gansu Province,China(No.17ZD2GC011)the Hongliu First-class Discipline Construction Plan of Lanzhou University of Technology,China(No.CGZH001).
基金Supported by Basic Research Project of Science and Technology Plan of Shenzhen(Grant No.JCYJ20170817111811303).
文摘New materials and manufacturing technologies require applicable non-destructive techniques for quality assurance so as to achieve better performance.This study comprehensively investigated the effect of influencing factors includ-ing excitation frequency,lift-off distance,defect depth and size,residual heat,and surface roughness on the defect EC signals of an Inconel 738LC alloy produced by selective laser melting(SLM).The experimental investigations recorded the impedance amplitude and phase angle of EC signals for each defect to explore the feasibility of detecting sub-surface defects by merely analyzing these two key indicators.Overall,this study revealed preliminary qualitative and roughly quantitative relationships between influencing factors and corresponding EC signals,which provided a prac-tical reference on how to quantitively inspect subsurface defects using eddy current testing(ECT)on SLMed parts,and also made solid progress toward on-line ECT in additive/subtractive hybrid manufacturing(ASHM)for fabricating SLMed parts with enhanced quality and better performance.
基金Project(08BZ1130100) supported by the Science and Technology Committee of Shanghai,ChinaProject(SHUCX102251) supported by the Innovation Fund for Graduate Student of Shanghai University,China
文摘The influence of casting parameters on stray grain formation of a unidirectionally solidified superalloy IN738LC casting with three platforms was investigated by using a 3D cellular automaton-finite element(CAFE) model in CALCOSOFT package.The model was first validated by comparison of the reported grain structure of Al-7%Si(mass fraction) alloy.Then,the influence of pouring temperature,heat flux of the lateral surface,convection heat coefficient of the cooled chill and mean undercooling of the bulk nucleation on the stray grain formation was studied during the unidirectional solidification.The predictions show that the stray grain formation is obviously sensitive to the pouring temperature,heat flux and mean undercooling of the bulk nucleation.However,increasing the heat convection coefficient has little influence on the stray grain formation.
基金The authors thank Isfahan University of technology for help with OM,SEM,and XRD.Special thank to Dr.F.Shahriari for his instruction and kindly cooperation.
文摘Up to now, the aluminide coatings used to protect industrial components at high temperature and corrosive environments have been modified by Pt, Cr, Si and Ni. In this investigation, aluminide coatings were modified by titanium and the microstructural feature and formation mechanism were evaluated. The coatings were formed on a Ni-based superalloy(IN738LC) by a two stage process including titanizing at first and aluminizing thereafter. Pack cementation titanizing performed at temperatures 950° C and 1050° C in several mixtures of Ti, A12O3 and NH^Cl. At the second stage, aluminum diffused into surface of the specimens by an industrial aluminizing process known as Elcoatl01(4 hrs at 1050° C). The modified coatings were characterized by means of standard optical microscopy, scanning electron microscopy, energy dispersive spectroscopy and X-Ray diffraction methods. The results show that Ti in the coatings is mainly present in the form of TiNi and Al67Cr8Ti25. Titanium modified coatings grew with a mechanism similar to simple aluminizing; this includes inward diffusion of Al from the pack to the substrate and then outward diffusion of Ni from the substrate to the coating. The advantages and characteristics of this two-stage modified coating is discussed and the process parameters are proposed to obtain a coating of optimum microstructure.
基金The authors appreciate Isfahan University of Technology for financial support.
文摘In this investigation, aluminide coatings used to protect industrial components at high temperature and corrosive environments were modified with silicon addition and the microstructural features and formation mechanism were evaluated. The coating on the nickel-based superalloy IN738LC was carried out by a two stage process including siliconizing at first and aluminizing thereafter. Pack cementation siliconizing performed at 950C for 2, 4 and 6 hours in several powder mixtures of Si, A12O3 and NHiCl, then aluminum was diffused into the surface of the specimens by an industrial aluminizing process. The modified coatings were characterized by means of standard metallography, scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction methods. The results show that Si in the coatings mainly presents in the form of secondary phases including Cr3Si, Mo5Si3 and Nii6Ti6Si7, well distributed within the NiAl matrix. The advantages of this two stage modified coating is discussed.
文摘Transient liquid phase（TLP） bonding of IN738 LC superalloy was carried out using a rapidly solidified MBF-15 Ni-based foil. The effects of bonding temperature（1130–1170 °C） and time（5–120 min） as well as foil thickness（35–140 μm） were studied on the microstructure of joint region and its mechanical properties. The solidification sequence in the joint region was found to be（i） formation of γ solid solution in the isothermally solidified zone, followed by（ii） ternary eutectic of γ ＋ Ni3 B ＋ Cr B, and finally（iii） binary eutectic of γ ＋ Ni3 Si in the athermally solidified zone. Fine Ni3 Si particles were also formed via a solid state transformation within the γ matrix in the vicinity of eutectic products. A deviation of isothermal solidification kinetics from the standard parabolic TLP model was observed by increasing the bonding temperature to 1170 °C, which resulted in the formation of eutectic constituents at the joint centerline.The analysis of mechanical and fractographic test results revealed that the samples with complete isothermal solidification exhibit the highest shear strength, whereas the hard eutectic constituents act as preferential failure sites and lead to a significant reduction in the joint shear strength in samples with incomplete isothermal solidification.
基金the Fundamental Research Program of the Korea Institute of Materials Science(Grant No.PNK5520)Korea Institute for Advancement of Technology(KIAT)grant funded by the Korea Government(MOTIE)(P0002007,The Competency Development Program for Industry Specialist)。
文摘The present study investigated the effect of as-built and post heat-treated microstructures of IN738LC alloy fabricated via selective laser melting process on high temperature oxidation behavior.The as-built microstructure showed fine cell and columnar structure due to high cooling rate.Ti element segregation was observed in inter-cell/inter-columnar area.After post heat-treatment,the initially-observed cell structure disappeared,instead bimodal Ni_3(Al,Ti)particles formed.High temperature(1273 K and 1373 K)oxidation test results showed parabolic oxidation curves regardless of temperature and initial microstructure.The as-built IN738LC fabricated via the selective laser melting process displayed oxidation resistance similar to or slightly better than that of IN738LC fabricated via wrought or cast process.Heat-treated SLM IN738LC,although had similar oxidation weight-gain values to those of the SLM asbuilt material at 1273K,showed relatively better oxidation resistance at 1373 K.Bimodal Ni_3(Al,Ti)precipitate formed in the post heat treatment changed the local chemical composition,thereby led to changes in alumina former/chromia former location and fraction on the alloy surface.It was concluded that in heat-treated IN738LC increased alumina former fraction was found,and this resulted in excellent oxidation resistance and relatively low weight-gain.
基金financially supported by"Industrial Transformation Research Hub for Transforming Australia’s Manufacturing Industry through High Value Additive Manufacturing"of the Australian Research Council(grant No.IH130100008)the use of instruments and scientific and technical assistance at the Monash Centre for Electron Microscopy,a Node of Microscopy Australiathe financial support from the Monash Graduate Research Scholarship(MGS)and International Monash Postgraduate Research Scholarship(IMPRS)from the Monash University。
文摘Nickel-based superalloy IN738LC produced by selective laser melting(SLM)exhibits inferior hightemperature creep properties than its cast counterparts due to relatively smaller grain size,particularly for the plane normal to the building direction.This work studied effects of post heating strategy on the microstructure and especially the grain size to improve the high temperature creep resistance.The asbuilt microstructure exhibited a fine grain size and large quantities of MC carbides that could effectively hinder grain growth.It was found that unconventional two-step heat treatments could lead to substantial grain growth,and the effect is particularly prominent at a specific temperature.The ease of grain growth was explained after classifying the microstructural evolution(boundary carbide transformation)during each heating step and related to the reduced grain boundary pinning force from MC carbides.Creep tests validated the effect of the new heat treatment scheme on the SLM-processed IN738LC at 850℃.An extended creep fracture life(1.5 to 4 times improvement)and lower secondary creep rates were achieved with samples subjected to the newly optimized two-step heat treatment.The complete creep curves are also firstly presented for SLM-IN738LC,confirming the effectiveness of grain growth and highlighting the importance of dedicated heat treatment for SLM superalloys.
