Hot Compression Behavior and Tensile Property of a Novel Ni-Co-Based Superalloy Prepared by Electron Beam Smelting Layered Solidification Technology

The hot compression behavior and tensile strength after compression of a new Ni-Co-based superalloy produced using electron beam smelting layered(EBSL)solidification technology were investigated.Isothermal compression tests were performed at temperatures of 1120℃and 1150℃,with strain rates of 1 s^(-1) and 0.01 s^(-1),reaching a true strain of 0.51.Tensile strength was evaluated at room temperature.The results revealed that this EBSL technology accelerates dynamic recrystallization(DRX),without compromising the strength of alloy.A significant correlation between the volume fraction of DRX and the strain rate was observed,with higher fractions at lower strain rates,leading to higher tensile strength.Additionally,at the same strain rate,the specimens compressed at 1120℃exhibited higher tensile strength due to undissolvedγ′precipitates.After solution and aging heat treatment,the alloy maintained high tensile strength.The results suggested that the EBSL Ni-Co-based superalloy offers excellent prospects for practical applications.

Recrystallization Behavior of the New Ni-Co-Based Superalloy with Fusion Structure Produced by Electron Beam Smelting Layered Solidification Technology

The new Ni-Co-based superalloy featuring a"fusion structure"was produced utilizing electron beam smelting layered solidification technology(EBSL).Experimental examination of hot compression deformation with varied settings for EBSL and conventional duplex process melting Ni-Co superalloys was performed.As per the study,EBSL-Ni-Co superalloys exhibited enhanced recrystallization susceptibility during hot deformation.Furthermore,elevating deformation temperature,lowering strain rate,and augmenting strain collectively contribute to enlarging the volume fraction of dynamically recrystallized grains.Aberrant growth of grains occurred when the deformation temperature equaledγ′sub-solvus temperature and the strain rate was slower.Moreover,exceeding theγ′solvus temperature during deformation significantly increases the particle size of dynamic recrystallization(DRX)grains.Theγ′phase can effectively modulate the DRX grain size through the pegging effect.Additionally,it was revealed that the presence of the fusion structure aids in the generation of continuous dynamic recrystallization,discontinuous dynamic recrystallization,and twinning-induced dynamic recrystallization while the alloy undergoes hot deformation.This mechanism promotes DRX granule formation and permits complete recrystallization.Ultimately,the fusion structure was identified as playing a catalytic role in the dynamic recrystallization process of the new Ni-Co superalloy.

Deformation micro-twinning arising at high temperatures in a Ni-Co-based superalloy

Deformation twinning is an important deformation mechanism in nickel-based superalloys. For superalloys, deformation twins are generally observed at low or intermediate temperatures and high strain rates;however, the appearance of microtwins(MTs) at high temperatures has rarely been reported. In this study, transmission electron microscopy(TEM) was used to study MT formation in Ni-Co-based superalloys following compression at 1120 °C/1 s. The deformation behavior was discussed in detail to reveal the mechanism of MT formation. The twinning mechanism at elevated temperatures was theoretically attributed to the low stacking fault energy(SFE) and poor dislocation-driven deformations caused by the high strain rate in specific directions.

A review of linear friction welding of Ni -based superalloys

Ni-based superalloys are one of the most important materials employed in high-temperature applications within the aerospace and nuclear energy industries and in gas turbines due to their excellent corrosion,radiation,fatigue resistance,and high-temperature strength.Linear friction welding(LFW)is a new joining technology with near-net-forming characteristics that can be used for the manu-facture and repair of a wide range of aerospace components.This paper reviews published works on LFW of Ni-based superalloys with the aim of understanding the characteristics of frictional heat generation and extrusion deformation,microstructures,mechanical proper-ties,flash morphology,residual stresses,creep,and fatigue of Ni-based superalloy weldments produced with LFW to enable future optim-um utilization of the LFW process.

Competitive oxidation behavior of Ni-based superalloy GH4738 at extreme temperature

A high thrust-to-weight ratio poses challenges to the high-temperature performance of Ni-based superalloys. The oxidation behavior of GH4738 at extreme temperatures has been investigated by isothermal and non-isothermal experiments. As a result of the competitive diffusion of alloying elements, the oxide scale included an outermost porous oxide layer (OOL), an inner relatively dense oxide layer (IOL), and an internal oxide zone (IOZ), depending on the temperature and time. A high temperature led to the formation of large voids at the IOL/IOZ interface. At 1200℃, the continuity of the Cr-rich oxide layer in the IOL was destroyed, and thus, spallation occurred. Extension of oxidation time contributed to the size of Al-rich oxide particles with the increase in the IOZ. Based on this finding,the oxidation kinetics of GH4738 was discussed, and the corresponding oxidation behavior at 900-1100℃ was predicted.

Recent research progress in the mechanism and suppression of fusion welding-induced liquation cracking of nickel based superalloys

Nickel-based superalloys are extensively used in the crucial hot-section components of industrial gas turbines,aeronautics,and astronautics because of their excellent mechanical properties and corrosion resistance at high temperatures.Fusion welding serves as an effective means for joining and repairing these alloys;however,fusion welding-induced liquation cracking has been a challenging issue.This paper comprehensively reviewed recent liquation cracking,discussing the formation mechanisms,cracking criteria,and remedies.In recent investigations,regulating material composition,changing the preweld heat treatment of the base metal,optimizing the welding process parameters,and applying auxiliary control methods are effective strategies for mitigating cracks.To promote the application of nickel-based superalloys,further research on the combination impact of multiple elements on cracking prevention and specific quantitative criteria for liquation cracking is necessary.

Effect of Ti and Ta content on the oxidation resistance of Co-Ni-based superalloys

Co-Ni-based superalloys are known for their capability to function at elevated temperatures and superior hot corrosion and thermal fatigue resistance.Therefore,these alloys show potential as crucial high-temperature structural materials for aeroengine and gas turbine hot-end components.Our previous work elucidated the influence of Ti and Ta on the high-temperature mechanical properties of alloys.However,the intricate interaction among elements considerably affects the oxidation resistance of alloys.In this paper,Co-35Ni-10Al-2W-5Cr-2Mo-1Nb-xTi-(5−x)Ta alloys(x=1,2,3,4)with varying Ti and Ta contents were designed and compounded,and their oxidation resistance was investigated at the temperature range from 800 to 1000℃.After oxidation at three test conditions,namely,800℃for 200 h,900℃for 200 h,and 1000℃for 50 h,the main structure of the oxide layer of the alloy consisted of spinel,Cr_(2)O_(3),and Al_(2)O_(3)from outside to inside.Oxides consisting of Ta,W,and Mo formed below the Cr_(2)O_(3)layer.The interaction of Ti and Ta imparted the highest oxidation resistance to 3Ti2Ta alloy.Conversely,an excessive amount of Ti or Ta resulted in an adverse effect on the oxidation resistance of the alloys.This study reports the volatilization of W and Mo oxides during the oxidation process of Co-Ni-based cast superalloys with a high Al content for the first time and explains the formation mechanism of holes in the oxide layer.The results provide a basis for gaining insights into the effects of the interaction of alloying elements on the oxidation resistance of the alloys they form.

Transient liquid phase bonding of DD5 superalloy using a designed interlayer: microstructure and mechanical properties

Nickel based single crystal superalloy is currently widely used as the material for turbine blades in aerospace engines.However,metallurgical defects during the manufacturing process and damage during harsh environmental service are inevitable challenges for turbine blades.Therefore,bonding techniques play a very important role in the manufacturing and repair of turbine blades.The transient liquid phase(TLP)bonding of DD5 Ni-based single crystal superalloy was performed using the designed H1 interlayer.A new third-generation Ni-based superalloy T1 powder was mixed with H1 powder as another interlayer to improve the mechanical properties of the bonded joints.The res-ults show that,such a designed H1 interlayer is beneficial to the improvement of shear strength of DD5 alloy bonded joints by adjusting the bonding temperature and the prolongation of holding time.The maximum shear strength at room temperature of the joint with H1 interlayer reached 681 MPa when bonded at 1260℃for 3 h.The addition of T1 powder can effectively reduce holding time or relatively lower bond-ing temperature,while maintaining relatively high shear strength.When 1 wt.%T1 powder was mixed into H1 interlayer,the maximum room temperature shear strength of the joint bonded at 1260℃reached 641 MPa,which could be obtained for only 1 h.Considering the bonding temperature and the efficiency,the acceptable process parameter of H1+5 wt.%T1 interlayer was 1240℃/2 h,and the room tem-perature shear strength reached 613 MPa.

A novel high-Cr CoNi-based superalloy with superior high-temperature microstructural stability, oxidation resistance and mechanical properties

A novel multicomponent high-Cr CoNi-based superalloy with superior comprehensive performance was prepared,and the evaluation of its high-temperature microstructural stability,oxidation resistance,and mechanical properties was conducted mainly using its cast polycrystalline alloy.The results disclosed that the morphology of theγ′phase remained stable,and the coarsening rate was slow during the long-term aging at 900–1000℃.The activation energy forγ′precipitate coarsening of alloy 9CoNi-Cr was(402±51)kJ/mol,which is higher compared with those of CMSX-4 and some other Ni-based and Co-based superalloys.Importantly,there was no indica-tion of the formation of topologically close-packed phases during this process.All these factors demonstrated the superior microstructural stability of the alloy.The mass gain of alloy 9CoNi-Cr was 0.6 mg/cm^(2) after oxidation at 1000℃ for 100 h,and the oxidation resistance was comparable to advanced Ni-based superalloys CMSX-4,which can be attributed to the formation of a continuous Al_(2)O_(3) protective layer.Moreover,the compressive yield strength of this cast polycrystalline alloy at high temperatures is clearly higher than that of the conventional Ni-based cast superalloy and the compressive minimum creep rate at 950℃ is comparable to that of the conventional Ni-based cast superalloy,demonstrating the alloy’s good mechanical properties at high temperature.This is partially because high Cr is bene-ficial in improving theγandγ′phase strengths of alloy 9CoNi-Cr.

Versatile fluidity test model for cast superalloys and comparison between IN718 and IN939

A spiral fluidity test model of superalloys with 10 mm in height and 3 mm in thickness was designed to evaluate the fluidity of two distinct Ni-based superalloys IN718 and IN939.The factors influencing fluidity are ascertained through comparative analysis utilizing methodologies such as JMat Pro,differential scanning calorimetry and high-temperature confocal laser scanning microscopy.The results show that under identical testing conditions,the fluidity of the IN939 superalloy surpasses that of the IN718 superalloy.When subjected to the same temperature,the melt viscosity and surface tension of IN939 superalloy are considerably reduced relative to those of IN718 superalloy,which is beneficial to improving the melt fluidity.Furthermore,the liquidus temperature and solidification range for the IN939 superalloy are both smaller compared with those of the IN718 superalloy.This condition proves advantageous in delaying dendrite coherency,thereby improving fluidity.

Cracking on a nickel-based superalloy fabricated by direct energy deposition

Cracks have consistently been a significant challenge limiting the development of additive manufactured nickel-based superalloys.It is essential to investigate the location of cracks and their forming mechanism.This study extensively examines the impact of solidification process,microstructural evolution,and stress concentration on crack initiation during direct energy deposition(DED).The results emphasize that the crack formation is significantly related to large-angle grain boundaries,rapid cooling rates.Cracks caused by large-angle grain boundaries and a fast-cooling rate predominantly appear near the edge of the deposited samples.Liquation cracks are more likely to form near the top of the deposited sample,due to the presence ofγ/γ'eutectics.The secondary dendritic arm and the carbides in the interdendritic regions can obstruct liquid flow during the final stage of solidification,which results in the formation of solidification cracks and voids.This work paves the way to avoid cracks in nickel-based superalloys fabricated by DED,thereby enhancing the performance of superalloys.

Oxidation behavior of 4774DD1 Ni-based single-crystal superalloy at 980℃ in air

The oxidation behavior of a novel Ni-based single-crystal 4774DD1 superalloy for industrial gas turbine applications was investigated by the isothermal oxidation at 980℃ and discontinuous oxidation weight gain methods.The phase constitution and morphology of surface oxides and the characteristics of the crosssection oxide film were analyzed by XRD,SEM and EDS.Results show that the oxidation kinetics of the 4774DD1 superalloy follows the cubic law,indicating its weak oxidation resistance at this temperature.As the oxidation time increases,the composition of the oxide film evolves as following:One layer consisting of a bottom Al_(2)O_(3)sublayer and an upper(Al_(2)O_(3)+NiO)mixture sublayer after oxidized for 25 h.Then,two layers composed of an outermost small NiO discontinuous grain layer and an internal layer for 75 h.This internal layer is consisted of the bottom Al_(2)O_(3)sublayer,an intermediate narrow CrTaO_(4)sublayer,and an upper(Al_(2)O_(3)+NiO)mixture sublayer.Also two layers comprising an outermost relative continuous NiO layer with large grain size and an internal layer as the oxidation time increases to 125 h.This internal layer is composed of the upper(Al_(2)O_(3)+NiO)mixture sublayer,an intermediate continuous(CrTaO_(4)+NiWO_(4))mixture sublayer,and a bottom Al_(2)O_(3)sublayer.Finally,three layers consisting of an outermost(NiAl2O_(4)+NiCr2O_(4))mixture layer,an intermediate(CrTaO_(4)+NiWO_(4))mixture layer,and a bottom Al_(2)O_(3)layer for 200 h.

Structure characterization of the oxide film on FGH96 superalloy powders with various oxidation degrees

The structure of the oxide film on FGH96 alloy powders significantly influences the mechanical properties of superalloys.In this study,FGH96 alloy powders with various oxygen contents were investigated using high-resolution transmission electron microscopy and atomic probe technology to elucidate the structure evolution of the oxide film.Energy dispersive spectrometer analysis revealed the presence of two distinct components in the oxide film of the alloy powders:amorphous oxide layer covering the γ matrix and amorphous oxide particles above the carbide.The alloying elements within the oxide layer showed a laminated distribution,with Ni,Co,Cr,and Al/Ti,which was attributed to the decreasing oxygen equilibrium pressure as oxygen diffused from the surface into the γ matrix.On the other hand,Ti enrichment was observed in the oxide particles caused by the oxidation and decomposition of the carbide phase.Comparative analysis of the oxide film with oxygen contents of 140,280,and 340 ppm showed similar element distributions,while the thickness of the oxide film varies approximately at 9,14,and 30 nm,respectively.These findings provide valuable insights into the structural analysis of the oxide film on FGH96 alloy powders.

Effect of hot isostatic pressure on the microstructure and tensile properties of γ'-strengthened superalloy fabricated through induction-assisted directed energy deposition

The microstructure characteristics and strengthening mechanism of Inconel738LC(IN-738LC) alloy prepared by using induction-assisted directed energy deposition(IDED) were elucidated through the investigation of samples subjected to IDED under 1050℃ preheating with and without hot isostatic pressing(HIP,1190℃,105 MPa,and 3 h).Results show that the as-deposited sample mainly consisted of epitaxial columnar crystals and inhomogeneously distributed γ’ phases in interdendritic and dendritic core regions.After HIP,grain morphology changed negligibly,whereas the size of the γ’ phase became increasingly even.After further heat treatment(HT,1070℃,2 h + 845℃,24 h),the γ’ phase in the as-deposited and HIPed samples presented a bimodal size distribution,whereas that in the as-deposited sample showed a size that remained uneven.The comparison of tensile properties revealed that the tensile strength and uniform elongation of the HIP + HTed sample increased by 5% and 46%,respectively,due to the synergistic deformation of bimodal γ’phases,especially large cubic γ’ phases.Finally,the relationship between phase transformations and plastic deformations in the IDEDed sample was discussed on the basis of generalized stability theory in terms of the trade-off between thermodynamics and kinetics.

Interface healing mechanism of fine-grained Ni-Co-based superalloy during hot-compression bonding

The interface healing mechanism of fine-grained Ni-Co-based superalloy during hot-compression bonding(HCB)is investigated.During HCB,the incompatibility of deformation between theγand the primary γ′leads to a large number of dislocation pairs(DP),stacking faults(SF),and micro-twins(MT)in the primary γ′.These defects act as fast channels for elemental diffusion,leading to supersaturation of the primary γ′and promoting the growth of the γ-shell.On the one hand,the primary γ′with a γ-shell moves towards the bonding interface due to anomalous yielding phenomena of the primary γ′and plastic flow during HCB process.The increase in the number of defects leads to the growth of γ-γ′heterogeneous epitaxial recrystallization(HERX)grain with coherent structure at the bonding interface,which promotes the bulge of the interface grain boundaries(IGBs).On the other hand,the nucleation and growth of a necklace-like distribution of discontinuous dynamic recrystallization(DDRX)grain at the interface lead to the healing of IGBs.With the synergistic action of DDRX and HERX,the mechanical properties of Ni-Co-based superalloy joints through HCB achieve the same level as the base material.This finding further enriches the theory of interface healing in HCB.

MICROSTRUCTURE AND MECHANICAL PROPERTIES OF Fe-Ni-Co-BASE SUPERALLOY AFTER LONGTERM AGING AT 650℃

The microstructure and mechanical properties of a Ni-Fe-Co base superalloy with low thermal expansion coefficient after aging at 650℃ for 200,500,1000 and 2000 h have been investigated.It was found that they are stable at 650℃.This alloy is believed to.fill the re- quirements for long time service to aircraft engine.

Microstructure,segregation and precipitate evolution in directionally solidified GH4742 superalloy

The evolution of microstructure,elemental segregation,and precipitation in GH4742 superalloy under a wide range of cooling rates was investigated using zonal melting liquid metal cooling(ZMLMC) experiments.Comparing various nickel-based superalloys,the primary dendrite spacing is significantly linearly correlated with G^(-1/2)V^(-1/4) at high cooling rates,where G and V are temperature gradient and drawing rate,respectively.As the cooling rate decreases,the primary dendrite spacing increases in a dispersive manner.The secondary dendrite arm spacing is significantly correlated with(GV)^(-0.4) for all cooling rate ranges.The degree of elemental segregation increases and then decreases as the cooling rate increases,which is due to the competition between solute counter-diffusion and dendrite tip subcooling.With increasing the solidification rate,the size of γ′,carbides,and non-metallic inclusions gradually decreases.The morphology of the γ′ precipitate changes from plume-like to cubic to spherical.The morphology of carbide changes from block to fine-strip then to Chinese-script.The morphology of carbide is controlled by both dendrite interstitial shape and element diffusion.The inclusions are mainly composite inclusions,which usually show the growth of Ti(C,N) with oxide as the heterogeneous nucleation center and carbide on the outer surface of the carbonitride.As the cooling rate increases,the number density of composite inclusions first increases and then decreases,which is closely related to the elemental segregation behavior.

Effect of the capsule on deformation and densification behavior of nickel-based superalloy compact during hot isostatic pressing

The Shima yield criterion used in finite element analysis for nickel-based superalloy powder compact during hot isostatic pressing(HIP) was modified through uniaxial compression experiments. The influence of cylindrical capsule characteristics on FGH4096M superalloy powder compact deformation and densification behavior during HIP was investigated through simulations and experiments. Results revealed the simulation shrinkage prediction fitted well with the experimental shrinkage including a maximum shrinkage error of 1.5%. It was shown that the axial shrinkage was 1.7% higher than radial shrinkage for a cylindrical capsule with the size of ∮50 mm × 100 mm due to the force arm difference along the axial and radial direction of the capsule. The stress deviated from the isostatic state in the capsule led to the uneven shrinkage and non-uniform densification of the powder compact. The ratio of the maximum radial displacement to axial displacement increased from0.47 to 0.75 with the capsule thickness increasing from 2 to 4 mm. The pressure transmission is related to the capsule thickness, the capsule material performance, and physical parameters in the HIP process.

Additive manufacturing of Ni-based superalloys: Residual stress, mechanisms of crack formation and strategies for crack inhibition

The additive manufacturing(AM)of Ni-based superalloys has attracted extensive interest from both academia and industry due to its unique capabilities to fabricate complex and high-performance components for use in high-end industrial systems.However,the intense temperature gradient induced by the rapid heating and cooling processes of AM can generate high levels of residual stress and metastable chemical and structural states,inevitably leading to severe metallurgical defects in Ni-based superalloys.Cracks are the greatest threat to these materials’integrity as they can rapidly propagate and thereby cause sudden and non-predictable failure.Consequently,there is a need for a deeper understanding of residual stress and cracking mechanisms in additively manufactured Ni-based superalloys and ways to potentially prevent cracking,as this knowledge will enable the wider application of these unique materials.To this end,this paper comprehensively reviews the residual stress and the various mechanisms of crack formation in Ni-based superalloys during AM.In addition,several common methods for inhibiting crack formation are presented to assist the research community to develop methods for the fabrication of crack-free additively manufactured components.

Elastic-viscoplastic constitutive equations of K439B superalloy and thermal stress simulation during casting process

K439B nickel-based superalloy is a new type of high-temperature material.There is insufficient research on its constitutive equations and numerical modeling of thermal stress.Isothermal tensile experiments of K439B superalloy at different temperatures(20°C-1,000°C)and strain rates(1.33×10^(-3)s^(-1)-5.33×10^(-3)s^(-1))were performed by using a Gleeble-3800 simulator.The elastic moduli at different temperatures(20°C-650°C)were measured by resonance method.Subsequently,stress-strain curves were measured for K439B superalloy under different conditions.The elastic-viscoplastic constitutive equations were established and the correspongding parameters were solved by employing the Perzyna model.The verification results indicate that the calculated values of the constitutive equations are in good agreement with the experimental values.On this basis,the influence of process parameters on thermal stress was investigated by numerical simulation and orthogonal experimental design.The results of orthogonal experimental design reveal that the cooling mode of casting has a significant influence on the thermal stress,while pouring temperature and preheating temperature of shell mold have minimal impact.The distribution of physical fields under optimal process parameters,determined based on the orthogonal experimental design results,was simulated.The simulation results determine separately the specific positions with maximum values for effective stress,plastic strain,and displacement within the casting.The maximum stress is about 1,000.0 MPa,the plastic strain is about 0.135,and the displacement is about 1.47 mm.Moreover,the distribution states of thermal stress,strain,and displacement are closely related to the distribution of the temperature gradient and cooling rate in the casting.The research would provide a theoretical reference for exploring the stress-strain behavior and numerical modeling of the effective stress of the alloy during the casting process.