Isothermal forging process design for spray-formed FGH95 superalloy turbine disk based on numerical simulation

Based on the experimental data from hot compression tests on Gleeble 1500 thermal simulator, the revised constitutive equations of spray-formed FGH95 superalloy considering the effect of strain on the material constants were established. The average absolute relative error （AARE） was employed to verify the validity of the constitutive equation, and the value of AARE is 3.85 %. Subsequently, the revised constitutive equations were successfully used to simulate and analyze the deformation behavior, stress distribution, forming loads and temperature distribution in both dies and billet during the isothermal forging process of turbine disk of large dimension （about 400 mm in diameter） by the means of finite element method （FEM）. Moreover, the optimum process parameters are 1,120 ℃ of forging temperature and 0.01 s^-1 of strain rate for the spray-formed FGH95 superalloy turbine disk.

Effects of Salt Quenching Temperatures on Microstructure and Creep Properties of a PM Ni-based Superalloy

By means of the microstructure observation and creep properties measurement, an investigation has been made into the influence of the salt quenching temperatures on the microstructure and creep property of FGH95 superalloy. The results shown that, after full heat treatment, a high volume of g￠ phase and some granular carbide dispersedly precipitate in the matrix. Thereinto, as the molten salt temperature decreases from 650℃to520℃, the size of fine g￠ phase in the alloy decrease gradually and the amount of carbides increase in the alloy. And the alloy quenched in molten salt at520℃possesses better creep resistance due to the fact that there are more granular carbides precipitating in the alloy to enhance the grain strength. During creep, the deformation features of the alloy are that the configurations of stacking fault and slipping dislocations are activated in the alloy.

Creep Behaviors of FGH95 Powder Ni-Base Superalloy

This article makes an investigation into the creep behavior and deformation features of FGH95 powder Ni-base superalloy by means of creep curves and microstructural observation. Results show that this superalloy exposes obvious sensibility to the applied temperature and stresses in the experimental range. Microstructure of the alloy consists of γ＇ phase of various sizes and dispersed carbide particles precipitated in the wider crystal boundaries between the powder particles. During the creep, the deformation of the alloy occurs in the form of singleor double-oriented slipping inside the grains, and some of the finer carbide particles are precipitated near the slipping traces. The wide grain boundaries might be broken into the finer grains due to severe deformation. The deformation mechanism of the alloy during creep is thought to be the activation of dislocations of double-oriented slipping, including （1/2）〈 110〉 dislocation inside the γ matrix phase and 〈110〉 super-dislocation inside the γ＇phase. The formation of the stacking faults and （1/3）〈112〉 super-Shockleys partial dislocation configuration is attributed to the decomposition of 〈 110〉 super-dislocation in the γ＇ phase.

Surface characteristics of rapidly solidified nickel-based superalloy pow-ders prepared by PREP

The surface microstructure and the surface segregation of FGH 95 nickel-basedsuperalloy powders prepared through plasma rotating electrode processing (PREP) have beeninvestigated by using SEM and AES. The results indicate that the surface microstructure of powderschanges from dendrite into cellular stricture as the particle size of powders decrease, and thepredominant precipitates solidified on the particle surfaces were identified as MC' type carbidesenriched with Nb and Ti. It was also indicated that along with the depth of particle surfaces, thesegregation layer of S, C and O elements are thick, and that of Ti, Cr elements are thin for largesire powders while they are in reverse for median size particles.

Influence of Processing Parameters on Granularity Distribution of Superalloy Powders during PREP

In order to investigate the influence of processing parameters on the granularity distribution of superalloy powders during the atomization of plasma rotating electrode processing (PREP), in this paper FGH95 superalloy powders is prepared under different processing conditions by PREP and the influence of PREP processing parameters on the granularity distribution of FGH95 superalloy powders is discussed based on fractal geometry theory. The results show that with the increase of rotating velocity of the self-consuming electrode, the fractal dimension of the granularity distribution increases linearly, which results in the increase of the proportion of smaller powders. The change of interval between plasma gun and the self-consuming electrode has a little effect on the granularity distribution, also the fractal dimension of the granularity distribution changed a little correspondingly.

Flow Behavior and Numerical Simulation of Spray-Formed FGH95 Superalloy Under Hot Compression

The flow behavior of spray-formed FGH95 superalloy （similar to Rene 95） was investigated at tempera- tures ranging from 1050 to 1 140 ℃ and strain rate ranging from 0.01 to 10 s-1. At a given temperature and strain rate, flow stress increases quickly with increasing strain and then reaches a peak, then gradual decreases until high strain, and dynamic softening is observed. Utilizing the hyperbolic sine {unction and introducing the strain with non- linear fitting, the revised constitutive equations incorporating the effects of temperature, strain rate and strain for high temperature flow stress prediction of superalloy were established. The revised constitutive equations were im- planted into finite element software by second development to simulate the hot compression process successfully, and the effective stress and load stroke curves obtained by numerical simulation are good agreement with the experimen- tal results.

Microstructure,Tensile Properties and Heat Treatment Process of Spray Formed FGH95 Superalloy

The potential of spray forming for microstructural refining can be attractive to the production of superalloys.A200mm spray formed FGH95superalloy round billet that was produced using a single atomizer has considerably homogeneous,small,equiaxed grains.The measured oxygen content is 2×10-5,and the measured porosity is only 0.6%.The achieved yield of deposit is in a good range of about 73.6%.The microstructure and tensile properties of nickel-based spray formed FGH95superalloy are analyzed.Also,effects of heat treatment on microstructure were discussed.The results show that the spray formed FGH95superalloy has higher isotropy in tensile property due to itsγ′phase homogeneous distribution and less defects in the microstructure.Regarding processing procedures,the different heat treatment processes affect the microstructure andγ′phase homogeneous distribution of spray formed FGH95superalloy.

Cellular automata simulation of grain growth of powder metallurgy Ni-based superalloy

Primary γ'phase instead of carbides and borides plays an important role in suppressing grain growth during solution at 1433 K of Ni-based FGH98 superalloys.Results illustrate that as-fabricated FGH98 superalloy has equiaxed grain structure,and after heat treatment,grains remain equiaxed but grow larger.In order to clarify the effects of the size and volume fraction of the primaryγ'phase on the grain growth during heat treatment,a 2D cellular automata(CA)model was established based on the thermal activation and the lowest energy principle.The CA results are compared with the experimental results and show a good fit with an error less than 10%.Grain growth kinetics are depicted,and simulations in real time for various sizes and volume fractions of primaryγ'particles work out well with the Zener relation.The coefficient n value which reflects the pinning ability in Zener relation is theoretically calculated,and its minimum value is 0.23 when the radius of primaryγ'phase is 2.8μm.

Microstructure Characterization and Mechanical Properties of FGH 95 Turbine Blade Retainers

FGH 95 is a powder metallurgy （P/M） processed superalloy, which was developed in the 1980s in China. One of the applications of FGH 95 was high pressure turbine blade retainers. The manufacturing processes used to produce FGH 95 blade retainers consisted of atomization by plasma rotating electrode process （PREP）, hot isostatic pressing （HIP） at super-solvus temperature and a sub-solvus solution heat treatment. The material had an equiaxed grain structure （ASTM 6.5-7.5）. The γ precipitates in as-HIP FGH 95 showed a tri-model distribution. Carbides in the alloy were MC type and precipitated at grain boundaries. The prior particle boundaries （PPB） in the material originated mainly from γ＇ phase. Statistics of the mechanical properties data from batch production of the FGH 95 blade retainers were investigated. The as-HIP FGH 95 blade retainers showed high strength at room temperature and 650 ℃, excellent creep resistance and outstanding stress rupture strength at 650 ℃.