Microstructure and mechanical properties of nickel-based superalloy fabricated by laser powder-bed fusion using recycled powders

Evaluating the recyclability of powders in additive manufacturing has been a long-term challenge.In this study,the microstructure and mechanical properties of a nickel-based superalloy fabricated by laser powder-bed fusion(LPBF)using recycled powders were investigated.Re-melted powder surfaces,satellite particles,and deformed powders were found in the recycled powders,combined with a high-oxygencontent surface layer.The increasing oxygen content led to the formation of high-density oxide inclusions;moreover,printing-induced cracks widely occurred and mainly formed along the grain boundaries in the as-built LPBF nickel-based superalloys fabricated using recycled powders.A little change in the Si or Mn content did not increase the hot cracking susceptibility(HCS)of the printed parts.The changing aspect ratio and the surface damage of the recycled powders might contribute to increasing the crack density.Moreover,the configuration of cracks in the as-built parts led to anisotropic mechanical properties,mainly resulting in extremely low ductility vertical to the building direction,and the cracks mainly propagated along the cellular boundary owing to the existence of a brittle precipitation 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.

THE ROLE OF NIOBIUM IN NICKEL-BASED SUPERALLOYS AND CHARACTERIZATION OF PM ALLOY EP741NP

The role of niobium in nickel-based superalloys is reviewed. The importance of niobium as a strengthener is discussed. New developments in nickel-based superalloys are also briefly mentioned, including some results that show improved resistance to sulfidation by niobium. Research results from a current program on the role of niobium in the Russian powder metallurgy alloy EP741NP are presented. Future research plans on the role of niobium in superalloys are also discussed.

Gaussian process regressions on hot deformation behaviors of FGH98 nickel-based powder superalloy

The hot deformation behaviors of FGH98 nickel-based powder superalloy were experimentally investigated and theoretically analyzed by Arrhenius models and machine learning(ML).Hot compression tests were conducted with a Gleeble-3800 thermo-mechanical simulation machine on the FGH98 superalloy at strain rates of 0.001–1 s–1 and temperatures of 1025–1175℃.The peak stresses under different deformation conditions were analyzed via the Sellars model and an ML-inspired Gaussian process regression(GPR)model.The prediction of the GPR model outperformed that from the Sellars model.In addition,the stress-strain responses were predicted by the GPR model and tested by experimentally measured stress-strain curves.The results indicate that the developed GPR model has great power with wide generalization capability in the prediction of hot deformation behaviors of FGH98 superalloy,as evidenced by the R2 value higher than 0.99 on the test dataset.

Prediction on grinding force during grinding powder metallurgy nickel-based superalloy FGH96 with electroplated CBN abrasive wheel

In this article,a grinding force model,which is on the basis of cutting process of single abrasive grains combined with the method of theoretical derivation and empirical formula by analyzing the formation mechanism of grinding force,was established.Three key factors have been taken into accounts in this model,such as the contact friction force between abrasive grains and materials,the plastic deformation of material in the process of abrasive plowing,and the shear strain effect of material during the process of cutting chips formation.The model was finally validated by the orthogonal grinding experiment of powder metallurgy nickel-based superalloy FGH96 by using the electroplated CBN abrasive wheel.Grinding force values of prediction and experiment were in good consistency.The errors of tangential grinding force and normal grinding force were 9.8%and 13.6%,respectively.The contributions of sliding force,plowing force and chip formation force were also analyzed.In addition,the tangential forces of sliding,plowing and chip formation are 14%,19%and 11%of the normal forces on average,respectively.The pro-posed grinding forcemodel is not only in favor of optimizing the grinding parameters and improving grinding efficiency,but also contributes to study some other grinding subjects(e.g.abrasive wheel wear,grinding heat,residual stress).

An investigation on machined surface quality and tool wear during creep feed grinding of powder metallurgy nickel-based superalloy FGH96 with alumina abrasive wheels

In this study,the machined surface quality of powder metallurgy nickel-based superalloy FGH96(similar to Rene88DT)and the grinding characteristics of brown alumina(BA)and microcrystalline alumina(MA)abrasive wheels were comparatively analyzed during creep feed grinding.The infuences of the grinding parameters(abrasive wheel speed,workpiece infeed speed,and depth of cut)on the grinding force,grinding temperature,surface roughness,surface morphology,tool wear,and grinding ratio were analyzed comprehensively.The experimental results showed that there was no significant difference in terms of the machined surface quality and grinding characteristics of FGH96 during grinding with the two types of abrasive wheels.This was mainly because the grinding advantages of the MA wheel were weakened for the difficult-to-cut FGH96 material.Moreover,both the BA and MA abrasive wheeIs exhibited severe tool wear in the form of wheel clogging and workpiece material adhesion.Finally,an analytical model for prediction of the grinding ratio was established by combining the tool wear volume,grinding force,and grinding length.The acceptable errors between the predicted and experimental grinding ratios(ranging from 0.6 to 1.8)were 7.56%and 6.31%for the BA and MA abrasive wheels,respectively.This model can be used to evaluate quantitatively the grinding performance of an alumina abrasive wheel,and is therefore helpful for optimizing the grinding parameters in the creep feed grinding process.

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.

Evolution of grain size and grain shape during thermomechanical processing in a powder metallurgical nickel-based superalloy

With a strain rate range of 0.01–10 s^(−1) and a deformation temperature range of 1110–1200℃,the isothermal compression test was performed on one powder metallurgy superalloy which is macroscopic segregation free.Using electron backscatter diffraction,the effect of strain rate and deformation temperature on grain shape and grain size of superalloys during thermal deformation was studied.The results established that exquisite and equiaxed dynamic recrystallization(DRX)grains are procured at supernal deformation temperature and high strain rate because of the high dislocation density.At the same time,the interaction between high DRX nucleation rate and low grain growth rate at high strain rate is favorable in making finer DRX grains.The equivalent medial grain size expanded with lowering strain rate and elevating proof temperature.Moreover,the grain shape was researched by the effective method of aspect ratio.Most aspect ratio of original grains is 0.61,and the aspect ratio has important implications for DRX and grain growth process.The average aspect ratio increases slightly when deformation temperature rises from 1110 to 1140℃,while the average aspect ratio increases memorably as the deformation temperature is higher than 1140℃.

Review on Additive Manufacturing of Single-Crystal Nickel-based Superalloys

The conventional fabrication process for single-crystal nickel-based superalloy materials is directional solidifica-tion,which is classified as casting.With the rapid development of additive manufacturing(AM)technologies,a novel process for fabricating single-crystal superalloys has become possible.This article reviews recent research on the AM of single-crystal nickel-based superalloys.Laser AM technologies,particularly directed energy deposition,are mainly used to repair single-crystal materials.Electron beam powder bed fusion is an innovative method for the direct fabrication of single-crystal materials.Accordingly,the mechanisms of single-crystal formation during AM are analyzed to elucidate the potential of this process route.Furthermore,this article discusses the challenges faced by AM for single-crystal fabrication,and provides perspectives on the trends of future developments.

Crack Types, Mechanisms, and Suppression Methods during High-energy Beam Additive Manufacturing of Nickel-based Superalloys: A Review

Nickel-based superalloys have been widely used in aerospace fields,especially for engine hot-end parts,because of their excellent high-temperature resistance.However,they are difficult to machine and process because of their special properties.High-energy beam additive manufacturing(HEB-AM)of nickel-based superalloys has shown great application potential in aerospace and other fields.However,HEB-AM of nickel-based superalloys faces serious cracking problems because of the unique characteristics of superalloys,and this has become the most significant bottleneck restricting their application.In this review,the current research status related to the types,formation mechanisms,and suppression methods of cracks in nickel-based superalloys produced by HEB-AM is described.The initiation and propagation mechanisms of cracks and their multiple influencing factors are also analyzed and discussed.Then,several possible research directions to solve the cracking problems in nickel-based superalloys produced by HEB-AM are outlined.This review provides an in-depth and comprehensive understanding of the cracking problem in AM nickel-based superalloys.It also provides valuable references for AM crack-free nickel-based superalloy components.

挤压态新型镍基粉末高温合金的热变形行为

镍基粉末高温合金的变形抗力大、热塑性较差、热加工窗口窄,而且在热加工过程中易产生裂纹和流动不稳定等缺陷。本文采用Gleeble−3500热模拟实验机对挤压态新型镍基粉末高温合金进行热压缩,压缩温度为1050~1150℃、应变速率为0.001~1 s^(−1),压缩真实应变为0.69。基于双曲正弦型Arrhenius函数,计算该合金的热激活能Q、构建本构方程,采用多项式拟合摩擦、温度变化、应变补偿的影响,对应力−应变曲线及本构方程进行修正,绘制能量耗散图和热加工图。结果表明:该合金的热激活能Q为536.36 kJ/mol,其在变形温度为1075~1150℃、应变速率为10^(−3)~10^(−1.5)s^(−1)的条件下有较好的加工性能,但当应变速率为0.001 s^(−1)时,晶粒组织较为粗大,γ′相溶入基体。

A comparing study of defect generation in IN738LC superalloy fabricated by laser powder bed fusion:Continuous-wave mode versus pulsed-wave mode

Inconel 738 LC samples were fabricated using laser powder bed fusion under continuous-wave and pulsed-wave modes.Microstructure,surface quality and mechanical properties were compared to evaluate the printing quality between these 2 laser beam modes.The results show that the application of pulsed wave could effectively eliminate cracking in the as-fabricated sample,despite 0.046%porosity generated.Further microstructure analysis revealed that the refinement of grains by the pulsed-wave laser beam was the main contributor in eliminating the cracks.And this refinement was ascribed to the higher cooling rate under the discontinuous radiation of laser beam proofed by the numerical simulation.And the pore formation was related to Rayleigh instability and residual bubbles in the sample under the pulsed-wave mode,while pores were less detrimental to the mechanical properties than cracks.Therefore,the part under the pulsed-wave mode exhibited superior mechanical performance compared to that under the continuous-wave mode.

Effects of TiC on the microstructure refinement and mechanical property enhancement of additive manufactured Inconel 625/TiC metal matrix composites fabricated with novel core-shell composite powder

The flexible product shape of additive manufacturing(AM)is attractive,but the process suffers from a lack of material property diversity due to a limited number of printable alloys and post-processing options.To overcome this problem,the AM of metal matrix composites(MMCs)is a highly suitable solution because the properties of MMC can be tailored using various reinforcements.Therefore,extensive research has been conducted on the AM of MMCs;however,the major huddle for this process has been the difficulties in preparing feedstock powder and operating the AM process.This study introduces an easily synthesizable core-shell composite powder,which was fabricated by a recently developed process called the SMART process.The core-shell powder has a novel morphology,consisting of a metal core and composite shell,distinguishing it from the powders used in conventional AM approaches.Inconel 625/TiCp composites were fabricated using the core-shell composite powder,with various fractions of TiCp up to 10 vol.%.Compared to additive-manufactured Inconel 625,the additive-manufactured MMCs showed enhanced strength with significantly fewer defects.The results of this study may accelerate the application of MMC fabricated by AM,which offers superior properties and reliability compared to casting and powder metallurgy due to the higher degree of dislocation density and reinforcement dispersion.

Effect of solution heat treatment and hot isostatic pressing on the microstructure and mechanical properties of Hastelloy X manufactured by electron beam powder bed fusion

Prior to the application of AM components for critical applications,it is necessary to have a better understanding of the effect of different post-fabrication treatments on the microstructure and mechanical properties of such parts.In this study,efforts were made to achieve an in-depth understanding of the effect of post-fabrication Solution Heat Treatment(SHT)and Hot Isostatic Pressing(HIP)on the microstructure and mechanical properties of Hastelloy X parts built by electron beam powder bed fusion(PBF-EB)process.The effects of SHT and HIP on porosity,microstructure,texture and mechanical properties have been investigated and compared with that of as-built PBF-EB Hastelloy X.Post-fabrication HIP treatment led to a significant reduction in the porosity content,whereas no notable difference in porosity was observed between SHT and as-built parts.There was no evidence of any recrystallization occurring following the post-fabrication treatments as elongated columnar grain structures observed within as-built part were found to be maintained even after SHT and HIP process alongside the strong<100>crystallographic texture.Emphasis was laid upon understanding the influence of SHT and HIP on mechanical properties through stress-strain curves and work-hardening behaviour.

挤压态镍基粉末高温合金微观组织分析

镍基粉末高温合金在挤压比为4∶1、挤压速度为20 mm·s^-1和变形温度为1050~1180℃的条件下进行挤压变形,将挤压后的试样在1000~1100℃条件下保温10~120 min,分析挤压态镍基粉末高温合金及其热处理过程中微观组织及再结晶晶粒的形核及长大。实验结果表明:挤压态镍基粉末高温合金中存在两种类型的γ′相,大尺寸γ′相多分布于晶界上,尺寸约为1~2μm,小尺寸γ′相多分布于晶粒内部,尺寸约为200 nm,呈弥散状态分布;经过1080和1100℃保温10,30,60和120 min的热处理后,大尺寸γ′相的含量和尺寸均变化不大,小尺寸γ′相基本完全溶解;热挤压变形过程中形成的位错胞,在加热过程中位错重新排列并对消形成亚晶,进而形成再结晶核心。再结晶核心通过应变能和界面能的驱动实现长大,由于合金中大尺寸γ′相的存在,在再结晶形核后的长大过程中,其晶界的迁移受γ′相的钉扎作用,抑制了晶粒长大,使合金晶粒组织具有良好的热稳定性。