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-isotherm...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.展开更多
The mosaic structure in a Ni-based single-crystal superalloy is simulated by molecular dynamics using a potential employed in a modified analytic embedded atom method. From the calculated results we find that a closed...The mosaic structure in a Ni-based single-crystal superalloy is simulated by molecular dynamics using a potential employed in a modified analytic embedded atom method. From the calculated results we find that a closed threedimensional misfit dislocation network, with index of (011){100} and the side length of the mesh 89.6A, is formed around a cuboidal γ′ precipitate. Comparing the simulation results of the different mosaic models, we find that the side length of the mesh only depends on the lattice parameters of the γ and γ′ phases as well as the γ/γ′ interface direction, but is independent of the size and number of the cuboidal γ′ precipitate. The density of dislocations is inversely proportional to the size of the cuboidal γ′ precipitate, i.e. the amount of the dislocation is proportional to the total area of the γ/γ′ interface, which may be used to explain the relation between the amount of the fine γ′ particles and the creep rupture life of the superalloy. In addition, the closed three-dimensional networks assembled with the misfit dislocations can play a significant role in improving the mechanical properties of superalloys.展开更多
An Ni-AI-Co system embedded-atom-method potential is constructed for the γ(Ni)/γ'(Ni3A1) superalloy based on experiments and first-principles calculations. The stacking fault energies (SFEs) of the Ni(Co, A1...An Ni-AI-Co system embedded-atom-method potential is constructed for the γ(Ni)/γ'(Ni3A1) superalloy based on experiments and first-principles calculations. The stacking fault energies (SFEs) of the Ni(Co, A1) random solid solutions are calculated as a function of the concentrations of Co and A1. The calculated SFEs decrease with increasing concentrations of Co and A1, which is consistent with the experimental results. The embedding energy term in the present potential has an important influence on the SFEs of the random solid solutions. The cross-slip processes of a screw dislocation in homogenous Ni(Co) solid solutions are simulated using the present potential and the nudged elastic band method. The cross-slip activation energies increase with increasing Co concentration, which implies that the creep resistance of γ(Ni) may be improved by the addition of Co.展开更多
The effect of H impurity on the misfit dislocation in Ni-based single-crystal superalloy is investigated using the molecular dynamic simulation. It includes the site preferences of H impurity in single crystals Ni and...The effect of H impurity on the misfit dislocation in Ni-based single-crystal superalloy is investigated using the molecular dynamic simulation. It includes the site preferences of H impurity in single crystals Ni and Ni3Al, the interaction between H impurity and the misfit dislocation and the effect of H impurity on the moving misfit dislocation. The calculated energies and simulation results show that the misfit dislocation attracts H impurity which is located at the γ/γ′ interface and Ni3Al and H impurity on the glide plane can obstruct the glide of misfit dislocation, which is beneficial to improving the mechanical properties of Ni based superalloys.展开更多
Single-crystal rods with different diameters and deviation angles with respect to the solidification direction were produced by Bridgman rapid solidification method at withdrawal rates of 3 and 6 mm·min^(-1) and ...Single-crystal rods with different diameters and deviation angles with respect to the solidification direction were produced by Bridgman rapid solidification method at withdrawal rates of 3 and 6 mm·min^(-1) and used as grain continuators.The crystallographic orientation of the rods,which cross-sections were perpendicular to the solidification direction at different solidification heights,was measured by electron backscattered diffraction,while the corresponding microstructures were observed by optical microscopy.The mushy zone morphology and the distribution of the temperature gradient were simulated by the finite element analysis software ProCAST.The experimental results indicate that the crystallographic orientation of the single-crystal rods corresponds to the statistical average value of all the dendrite orientations in cross-section.The crystallographic orientation of the primary and secondary dendrites of each single-crystal rod at different cross-sections fluctuates irregularly within a small range(less than 4°).The crystallographic orientation of the dendrite in each single-crystal rod is not exactly consistent with each other and is affected by their branching mode of dendrites in the solidification space.In addition,the simulation results show that the mushy zone shapes and the temperature gradient of single-crystal rods change with the increase of solidification height during the solidification process.Finally,the evolution mechanism of the crystallographic orientations and the corresponding influence factors were analyzed and discussed.展开更多
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 hig...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.展开更多
Stray grains are the most severe of the solidification defects that occur in the industrial single-crystal blade preparation process.In this study,a single-crystal dummy blade cluster with different crystal orientatio...Stray grains are the most severe of the solidification defects that occur in the industrial single-crystal blade preparation process.In this study,a single-crystal dummy blade cluster with different crystal orientations controlled by the seeding method was prepared,and the influence of the position of the circular platform(relative to the sample and furnace body)on stray grain nucleation was investigated.Results show that the microstructure of the circular platforms could be divided into the center,expansion,and stray grain regions.The inside of the circular platform facing the center of the cluster is more prone to stray grain formation than the outside of the circular platform facing the furnace body.With an increase in the distance between the circular platform and the bottom of the dummy blade cluster,the stray grain region expands,whereas the expansion region narrows.The stray grain is slightly aggravated with increase of the misorientation.Finally,the mechanism underlying the influence of platform position on the formation of stray grains in single-crystal dummy blade clusters is discussed based on the temperature evolution during directional solidification.展开更多
The rupture behavior of a cast Ni-base superalloy M963 at high temperature has been investi- gated. The microstructure examination shows that there exists a large amount of the carbide and γ-γ' eutectic, which i...The rupture behavior of a cast Ni-base superalloy M963 at high temperature has been investi- gated. The microstructure examination shows that there exists a large amount of the carbide and γ-γ' eutectic, which is very harmful to the mechanical properties of M963 superalloy. The tensile strength of M963 superalloy both at room temperature and at high temperatures is higher than that of K17G alloy, but the tensile ductility of the former is much lower than that of the latter. In tensile fracture process with the high strain rate, the open carbides are the initiation site and the carbide/matrix interface is the propagation path of cracks. But in fracture process with the low strain rate, the carbide/matrix interface and cast microvoids are the initiation sites, and the carbide/matrix interface is the propagation path of cracks. The effective ways to improve ductility of M963 superalloy are also suggested.展开更多
A single crystal Ni-based superalloy AM3 was processed at withdraw rates of 3.5, 10, 50, 100, 200, and 500 μm·s-1, respectively.The as-cast microstructures and solidification segregation ratio were characterized...A single crystal Ni-based superalloy AM3 was processed at withdraw rates of 3.5, 10, 50, 100, 200, and 500 μm·s-1, respectively.The as-cast microstructures and solidification segregation ratio were characterized with various withdraw rates.The shape and size of carbide microstructures were determined.As expected, the primary and secondary dendrite arm spacings (PDAS and SDAS) decrease with the increase of withdraw rate.The highest volume fraction of eutectic γ/γ' is observed at the 100 μm·s-1 withdraw rate.The volume fraction of eutectic γ/γ' does not appear to be a strong function of the withdraw rate.With increasing withdraw rate, interface morphologies change in the sequence of planar, cellular, and dendrite.There is a general refinement of the microstructure as the withdraw rate increases.EPMA analysis showed that withdraw rate does not have obvious influence on the segregation of elements.展开更多
Density functional theory calculations in conjunction with the climbing images nudged elastic band method are conducted to study the diffusion phenomena of the Ni-based single crystal superalloys.We focus our attentio...Density functional theory calculations in conjunction with the climbing images nudged elastic band method are conducted to study the diffusion phenomena of the Ni-based single crystal superalloys.We focus our attention on the diffusion processes of the Ni and Al atoms in the γ and γ ’ phases along the direction perpendicular to the interface.The diffusion mechanisms and the expressions of the diffusion coefficients are presented.The vacancy formation energies,the migration energies,and the activation energies for the diffusing Ni and Al atoms are estimated,and these quantities display the expected and clear transition zones in the vicinity of the interface of about 3–7(002) layers.The local density-of-states profiles of atoms in each(002) layer in the γ and γ ’ phases and the partial density-of-states curves of Re and some of its nearest-neighbor atoms are also presented to explore the electronic effect of the diffusion behavior.展开更多
In this study, the long-term thermal microstructural stability and related stress rupture lives of a new Re-containing Ni-based single-crystal superalloy, DD11, were investigated after high-temperature exposure for di...In this study, the long-term thermal microstructural stability and related stress rupture lives of a new Re-containing Ni-based single-crystal superalloy, DD11, were investigated after high-temperature exposure for different lengths of time. The results show that the γ' precipitates retained a cuboidal morphology and the γ' size increased after short thermal exposure for 50 h at 1,070℃. As the thermal exposure time was prolonged to 500 h, the cuboidal γ' gradually changed into irregular raft-like morphology due to particles coalescence, and the morphology of the microstructure was almost unchanged after further thermal exposure up to 3,000 h. The stress rupture experiments at 1,070℃ and a tensile stress of 140 MPa showed that the rupture lives increased significantly after thermal exposure for 50 h and dropped dramatically with increasing exposure time up to 500 h but decreased slowly after exposure for more than 500 h. These results imply that stress rupture properties did not decrease when the γ' remained cuboidal but degraded to different extents during the γ' coarsening process. The coarsening of the γ' precipitates and change in morphology were regarded as the main factors leading to the degradation of the stress rupture lives. This study provides fundamental information on the high-temperature longterm microstructural stability and mechanical performance, which will be of great help for DD11 alloy optimization and engineering aeroengine applications.展开更多
An anisotropic micromechanics model based on the equivalent inclusion method is developed to investigate the rafting direction of Ni-based single crystal superalloys. The micromechanical model considers actual cubic s...An anisotropic micromechanics model based on the equivalent inclusion method is developed to investigate the rafting direction of Ni-based single crystal superalloys. The micromechanical model considers actual cubic structure and orthogonal anisotropy properties. The von Mises stress, elastic strain energy density, and hydrostatic pressure in dif- ferent inclusions of micromechanical model are calculated when applying a tensile or compressive loading along the [001] direction. The calculated results can successfully pre- dict the rafting direction for alloys exhibiting a positive or a negative mismatch, which are in agreement with pervious experimental and theoretical studies. Moreover, the elastic constant differences and mismatch degree of the matrix and precipitate phases and their influences on the rafting direction are carefully discussed.展开更多
K416B Ni-based superalloy with high W content has good high temperature properties and low cost,which has a great development potential.To investigate the room temperature tensile property and the deformation feature ...K416B Ni-based superalloy with high W content has good high temperature properties and low cost,which has a great development potential.To investigate the room temperature tensile property and the deformation feature of K416B superalloy,tensile testing at room temperature was carried out,and optical microscopy (OM),scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were used to analyze the deformation and damage mechanisms.Results show that the main room temperature tensile deformation features of the K416B nickel-based superalloy are dislocations slipping in the matrix and shearing into γ’ phase.The <110> super-dislocations shearing into γ’ phase can form the anti-phase boundary two coupled (a/2)<110> partial-dislocations or decompose into the configuration of two (a/3)<112> partial dislocations plus stacking fault.In the later stage of tensile testing,the slip-lines with different orientations are activated in the grain,causing the stress concentration in the regions of block carbide or the porosity,and cracks initiate and propagate along these regions.展开更多
Three kinds of superalloys were prepared by spray deposited process. The analysis results of microstructures and mechanical properties indicate that the spray deposited preforms with higher integral densification and ...Three kinds of superalloys were prepared by spray deposited process. The analysis results of microstructures and mechanical properties indicate that the spray deposited preforms with higher integral densification and the oxygen content in each kind of superalloy was very low. The microstructures are consisted of fine grain without dendritic equi-axed. The spray deposited superalloys possessed good ductility. The forging experiment displays that even though the once deformation of spray deposited GH742 alloy more than 60%, the crack can not be found. Meanwhile, the mechanical properties of spray deposited superalloys are significantly increased.展开更多
In this study,a kind of Ni-based superalloy specially designed for additive manufacturing(AM)was investigated.Thermo-Calc simulation and differential scanning calorimetry(DSC)analysis were used to determine phases and...In this study,a kind of Ni-based superalloy specially designed for additive manufacturing(AM)was investigated.Thermo-Calc simulation and differential scanning calorimetry(DSC)analysis were used to determine phases and their transformation temperature.Experimental specimens were prepared by laser metal deposition(LMD)and traditional casting method.Microstructure,phase constitution and mechanical properties of the alloy were characterized by scanning electron microscopy(SEM),transmission scanning electron microscopy(TEM),X-ray diffraction(XRD)and tensile tests.The results show that this alloy contains two basic phases,γ/γ’,in addition to these phases,at least two secondary phases may be present,such as MC carbides and Laves phases.Furthermore,the as-deposited alloy has finer dendrite,its mean primary dendrite arm space(PDAS)is about 30-45μm,and the average size ofγ’particles is 100-150 nm.However,the dendrite size of the as-cast alloy is much larger and its PDAS is 300-500μm with secondary and even third dendrite arms.Correspondingly,the alloy displays different tensile behavior with different processing methods,and the as-deposited specimen shows better ultimate tensile stress(1,085.7±51.7 MPa),yield stress(697±19.5 MPa)and elongation(25.8%±2.2%)than that of the as-cast specimen.The differences in mechanical properties of the alloy are due to the different morphology and size of dendrites,γ’,and Laves phase,and the segregation of elements,etc.Such important information would be helpful for alloy application as well as new alloy development.展开更多
Low-cycle fatigue behavior of Ni-based superalloy GH586 with laser shock processing(LSP) was investigated. The residual stress of the specimens treated with LSP was assessed by X-ray diffraction method. The microstr...Low-cycle fatigue behavior of Ni-based superalloy GH586 with laser shock processing(LSP) was investigated. The residual stress of the specimens treated with LSP was assessed by X-ray diffraction method. The microstructure and fracture morphology were characterized by using an optical microscope(OM), a scanning electron microscope(SEM), and a transmission electron microscope(TEM). The results indicated that the maximum residual compressive stress was at about 1 mm from the shocking spot center, where the residual compressive stress was slightly lower. High density tangling dislocations, dislocation walls, and dislocation cells in the microstructure of the specimens treated with LSP effectively prevented fatigue cracks propagation. The fatigue life was roughly twice as long as that of the specimens without LSP. The fatigue crack initiation(FCI) in specimens treated with LSP was observed in the lateral section and the subsurface simultaneously. The fatigue striation in the fracture treated with LSP was narrower than that in the untreated specimens. Moreover, dimples with tear ridges were found in the fatigued zones of the LSP treated specimens, which would be caused by severe plastic deformation.展开更多
An analytical method to investigate the morphological evolution of the cellular mi-crostructure is explored and proposed. The method is essentially based on the Es-helby 's micromechanics theory, and it is extende...An analytical method to investigate the morphological evolution of the cellular mi-crostructure is explored and proposed. The method is essentially based on the Es-helby 's micromechanics theory, and it is extended so as to be applied for a material system containing inclusions with high volume fraction, by employing the average stress field approximation by Mori and Tanaka. The proposed method enables us to discuss a stable shape of precipitate in the material system, which must be influenced by many factors: e.g., volume fraction of precipitate; Young's modulus ratio and lattice misfit between matrix and precipitate; external stress field in multiaxial state; and heterogeneity of plastic strain between matrix and precipitate. A series of numerical calculations were summarized on stable shape maps. The application of the method to predict the γ' rafting in superalloys during creep showed that the heterogeneity of plastic strain between matrix and precipitates may play a significant role in the shape stability of the precipitate. Furthermore, it was shown that the method was successfully applied to estimate the morphology of the cellular microstructure formed in CMSX-4 single crystal Ni-based superalloy.展开更多
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,...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.展开更多
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...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.展开更多
Due to their superior combination of heat resistance, high temperature corrosion resistance, toughness and strength, nickel-based superalloys have become of extensive use in the aerospace industry. This research aims ...Due to their superior combination of heat resistance, high temperature corrosion resistance, toughness and strength, nickel-based superalloys have become of extensive use in the aerospace industry. This research aims to explain why the fatigue life of Inconel-718 in preconditioned samples had larger fatigue lives than pristine samples. The hypothesis is that preconditioning at 700°C and 1.0% strain could lead to thermal activation of the {100} cubic slip plane alongside the {111} octahedral slip plane, potentially improving fatigue life. Using SEM and EBSD imaging, the microstructure of Inconel-718 samples were characterized before and after preconditioning. The directions of the slip bands that formed following the preconditioning were determined. The result was that the existence of both the cubic and octahedral slip systems was confirmed, leading to the thermal activation hypothesized. The existence of both slip planes was considered to be the reason behind the improved fatigue life due to better strain accommodation within the microstructure. It is suggested that focuses for future research includes conducting in-situ observation of slip activation and the application of preconditioning as a manufacturing method.展开更多
基金financially supported by the National Key R&D Program of China (No.2021YFB3700400)the National Natural Science Foundation of China (Nos.52074030,51904021,and 52174294)。
文摘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.
基金Project supported by the State Key Development Program for Basic Research of China (Grant No G2000067102) and the National Natural Science Foundation of China (Grant No 90101004).
文摘The mosaic structure in a Ni-based single-crystal superalloy is simulated by molecular dynamics using a potential employed in a modified analytic embedded atom method. From the calculated results we find that a closed threedimensional misfit dislocation network, with index of (011){100} and the side length of the mesh 89.6A, is formed around a cuboidal γ′ precipitate. Comparing the simulation results of the different mosaic models, we find that the side length of the mesh only depends on the lattice parameters of the γ and γ′ phases as well as the γ/γ′ interface direction, but is independent of the size and number of the cuboidal γ′ precipitate. The density of dislocations is inversely proportional to the size of the cuboidal γ′ precipitate, i.e. the amount of the dislocation is proportional to the total area of the γ/γ′ interface, which may be used to explain the relation between the amount of the fine γ′ particles and the creep rupture life of the superalloy. In addition, the closed three-dimensional networks assembled with the misfit dislocations can play a significant role in improving the mechanical properties of superalloys.
基金Project supported by the National Basic Research Program of China(Grant No.2011CB606402)the National Natural Science Foundation of China(Grant No.51071091)
文摘An Ni-AI-Co system embedded-atom-method potential is constructed for the γ(Ni)/γ'(Ni3A1) superalloy based on experiments and first-principles calculations. The stacking fault energies (SFEs) of the Ni(Co, A1) random solid solutions are calculated as a function of the concentrations of Co and A1. The calculated SFEs decrease with increasing concentrations of Co and A1, which is consistent with the experimental results. The embedding energy term in the present potential has an important influence on the SFEs of the random solid solutions. The cross-slip processes of a screw dislocation in homogenous Ni(Co) solid solutions are simulated using the present potential and the nudged elastic band method. The cross-slip activation energies increase with increasing Co concentration, which implies that the creep resistance of γ(Ni) may be improved by the addition of Co.
基金supported by the National Basic Research Program of China (Grant No.2011CB606402)the National Natural Science Foundation of China (Grant No.51071091)
文摘The effect of H impurity on the misfit dislocation in Ni-based single-crystal superalloy is investigated using the molecular dynamic simulation. It includes the site preferences of H impurity in single crystals Ni and Ni3Al, the interaction between H impurity and the misfit dislocation and the effect of H impurity on the moving misfit dislocation. The calculated energies and simulation results show that the misfit dislocation attracts H impurity which is located at the γ/γ′ interface and Ni3Al and H impurity on the glide plane can obstruct the glide of misfit dislocation, which is beneficial to improving the mechanical properties of Ni based superalloys.
基金supported by the National Natural Science Foundation of China(No.51674235)the National Key Research and Development Program of China(Nos.2017-VI0001-0070 and 2017-VI-0019-0091)。
文摘Single-crystal rods with different diameters and deviation angles with respect to the solidification direction were produced by Bridgman rapid solidification method at withdrawal rates of 3 and 6 mm·min^(-1) and used as grain continuators.The crystallographic orientation of the rods,which cross-sections were perpendicular to the solidification direction at different solidification heights,was measured by electron backscattered diffraction,while the corresponding microstructures were observed by optical microscopy.The mushy zone morphology and the distribution of the temperature gradient were simulated by the finite element analysis software ProCAST.The experimental results indicate that the crystallographic orientation of the single-crystal rods corresponds to the statistical average value of all the dendrite orientations in cross-section.The crystallographic orientation of the primary and secondary dendrites of each single-crystal rod at different cross-sections fluctuates irregularly within a small range(less than 4°).The crystallographic orientation of the dendrite in each single-crystal rod is not exactly consistent with each other and is affected by their branching mode of dendrites in the solidification space.In addition,the simulation results show that the mushy zone shapes and the temperature gradient of single-crystal rods change with the increase of solidification height during the solidification process.Finally,the evolution mechanism of the crystallographic orientations and the corresponding influence factors were analyzed and discussed.
基金This work was supported by Shenzhen-Hong Kong Science and Technology Innovation Cooperation Zone Shenzhen Park Project:HZQB-KCZYB-2020030the National Natural Science Foundation of China(No.91860131and No.52074157)+2 种基金Guangdong Provincial Department of Science and Technology,Key-Area Research and Development Program of Guangdong Province(No.2020B090923002)the National Key Research and Development Program of China(No.2017YFB0702901)the Shenzhen Science and Technology Innovation Commission(No.JCYJ20170817111811303,No.KQTD20170328154443162and No.ZDSYS201703031748354).
文摘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.
文摘Stray grains are the most severe of the solidification defects that occur in the industrial single-crystal blade preparation process.In this study,a single-crystal dummy blade cluster with different crystal orientations controlled by the seeding method was prepared,and the influence of the position of the circular platform(relative to the sample and furnace body)on stray grain nucleation was investigated.Results show that the microstructure of the circular platforms could be divided into the center,expansion,and stray grain regions.The inside of the circular platform facing the center of the cluster is more prone to stray grain formation than the outside of the circular platform facing the furnace body.With an increase in the distance between the circular platform and the bottom of the dummy blade cluster,the stray grain region expands,whereas the expansion region narrows.The stray grain is slightly aggravated with increase of the misorientation.Finally,the mechanism underlying the influence of platform position on the formation of stray grains in single-crystal dummy blade clusters is discussed based on the temperature evolution during directional solidification.
基金supported by the Postdoctoral Science Foundation of China
文摘The rupture behavior of a cast Ni-base superalloy M963 at high temperature has been investi- gated. The microstructure examination shows that there exists a large amount of the carbide and γ-γ' eutectic, which is very harmful to the mechanical properties of M963 superalloy. The tensile strength of M963 superalloy both at room temperature and at high temperatures is higher than that of K17G alloy, but the tensile ductility of the former is much lower than that of the latter. In tensile fracture process with the high strain rate, the open carbides are the initiation site and the carbide/matrix interface is the propagation path of cracks. But in fracture process with the low strain rate, the carbide/matrix interface and cast microvoids are the initiation sites, and the carbide/matrix interface is the propagation path of cracks. The effective ways to improve ductility of M963 superalloy are also suggested.
基金supported by the National Natural Science Foundation of China (Grant No.50771081,50931004)the National Basic Research Program of China (2010CB631202)
文摘A single crystal Ni-based superalloy AM3 was processed at withdraw rates of 3.5, 10, 50, 100, 200, and 500 μm·s-1, respectively.The as-cast microstructures and solidification segregation ratio were characterized with various withdraw rates.The shape and size of carbide microstructures were determined.As expected, the primary and secondary dendrite arm spacings (PDAS and SDAS) decrease with the increase of withdraw rate.The highest volume fraction of eutectic γ/γ' is observed at the 100 μm·s-1 withdraw rate.The volume fraction of eutectic γ/γ' does not appear to be a strong function of the withdraw rate.With increasing withdraw rate, interface morphologies change in the sequence of planar, cellular, and dendrite.There is a general refinement of the microstructure as the withdraw rate increases.EPMA analysis showed that withdraw rate does not have obvious influence on the segregation of elements.
基金Project supported by National Basic Research Program of China(Grant No.2011CB606402)the National Natural Science Foundation of China(Grant No.51071091)
文摘Density functional theory calculations in conjunction with the climbing images nudged elastic band method are conducted to study the diffusion phenomena of the Ni-based single crystal superalloys.We focus our attention on the diffusion processes of the Ni and Al atoms in the γ and γ ’ phases along the direction perpendicular to the interface.The diffusion mechanisms and the expressions of the diffusion coefficients are presented.The vacancy formation energies,the migration energies,and the activation energies for the diffusing Ni and Al atoms are estimated,and these quantities display the expected and clear transition zones in the vicinity of the interface of about 3–7(002) layers.The local density-of-states profiles of atoms in each(002) layer in the γ and γ ’ phases and the partial density-of-states curves of Re and some of its nearest-neighbor atoms are also presented to explore the electronic effect of the diffusion behavior.
基金funded by the National High Technology Research and Development Program(No.2012AA03A513)
文摘In this study, the long-term thermal microstructural stability and related stress rupture lives of a new Re-containing Ni-based single-crystal superalloy, DD11, were investigated after high-temperature exposure for different lengths of time. The results show that the γ' precipitates retained a cuboidal morphology and the γ' size increased after short thermal exposure for 50 h at 1,070℃. As the thermal exposure time was prolonged to 500 h, the cuboidal γ' gradually changed into irregular raft-like morphology due to particles coalescence, and the morphology of the microstructure was almost unchanged after further thermal exposure up to 3,000 h. The stress rupture experiments at 1,070℃ and a tensile stress of 140 MPa showed that the rupture lives increased significantly after thermal exposure for 50 h and dropped dramatically with increasing exposure time up to 500 h but decreased slowly after exposure for more than 500 h. These results imply that stress rupture properties did not decrease when the γ' remained cuboidal but degraded to different extents during the γ' coarsening process. The coarsening of the γ' precipitates and change in morphology were regarded as the main factors leading to the degradation of the stress rupture lives. This study provides fundamental information on the high-temperature longterm microstructural stability and mechanical performance, which will be of great help for DD11 alloy optimization and engineering aeroengine applications.
基金supported by The National Natural Science Foundation of China (Grants 11102139 and 11472195)The Natural Science Foundation of Hubei Province of China (Grant 2014CFB713)
文摘An anisotropic micromechanics model based on the equivalent inclusion method is developed to investigate the rafting direction of Ni-based single crystal superalloys. The micromechanical model considers actual cubic structure and orthogonal anisotropy properties. The von Mises stress, elastic strain energy density, and hydrostatic pressure in dif- ferent inclusions of micromechanical model are calculated when applying a tensile or compressive loading along the [001] direction. The calculated results can successfully pre- dict the rafting direction for alloys exhibiting a positive or a negative mismatch, which are in agreement with pervious experimental and theoretical studies. Moreover, the elastic constant differences and mismatch degree of the matrix and precipitate phases and their influences on the rafting direction are carefully discussed.
基金financially supported by the National Basic Research Program of China(Nos.2010CB631200 and 2010CB631206)the National Natural Science Foundation of China(No.51701212,No.50931004,No.51571196,No.51601192 and No.51671188)+4 种基金the State Key Laboratory of Solidification Processing in NWPU(SKLSP201747)Liaoning Provincial Natural Science Foundation of China(No.2019-MS-336)the Key Regional Project of Science and Technology Service Network Program,Chinese Academy of Sciences(No.KFJ-STS-QYZX-079)the Youth Innovation Promotion Association Project,Chinese Academy of Sciences(2020)the National Science and Technology Major Project(J2019-VI-0018-0133)。
文摘K416B Ni-based superalloy with high W content has good high temperature properties and low cost,which has a great development potential.To investigate the room temperature tensile property and the deformation feature of K416B superalloy,tensile testing at room temperature was carried out,and optical microscopy (OM),scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were used to analyze the deformation and damage mechanisms.Results show that the main room temperature tensile deformation features of the K416B nickel-based superalloy are dislocations slipping in the matrix and shearing into γ’ phase.The <110> super-dislocations shearing into γ’ phase can form the anti-phase boundary two coupled (a/2)<110> partial-dislocations or decompose into the configuration of two (a/3)<112> partial dislocations plus stacking fault.In the later stage of tensile testing,the slip-lines with different orientations are activated in the grain,causing the stress concentration in the regions of block carbide or the porosity,and cracks initiate and propagate along these regions.
基金Funded by the Innovation Fund for Outstanding Scholar of Henan Province(No. 0621000700)
文摘Three kinds of superalloys were prepared by spray deposited process. The analysis results of microstructures and mechanical properties indicate that the spray deposited preforms with higher integral densification and the oxygen content in each kind of superalloy was very low. The microstructures are consisted of fine grain without dendritic equi-axed. The spray deposited superalloys possessed good ductility. The forging experiment displays that even though the once deformation of spray deposited GH742 alloy more than 60%, the crack can not be found. Meanwhile, the mechanical properties of spray deposited superalloys are significantly increased.
基金financially supported by the National Science and Technology Major Project(Y2019-Ⅶ-0011-0151)the National Natural Science Foundation of China(No.51771190)。
文摘In this study,a kind of Ni-based superalloy specially designed for additive manufacturing(AM)was investigated.Thermo-Calc simulation and differential scanning calorimetry(DSC)analysis were used to determine phases and their transformation temperature.Experimental specimens were prepared by laser metal deposition(LMD)and traditional casting method.Microstructure,phase constitution and mechanical properties of the alloy were characterized by scanning electron microscopy(SEM),transmission scanning electron microscopy(TEM),X-ray diffraction(XRD)and tensile tests.The results show that this alloy contains two basic phases,γ/γ’,in addition to these phases,at least two secondary phases may be present,such as MC carbides and Laves phases.Furthermore,the as-deposited alloy has finer dendrite,its mean primary dendrite arm space(PDAS)is about 30-45μm,and the average size ofγ’particles is 100-150 nm.However,the dendrite size of the as-cast alloy is much larger and its PDAS is 300-500μm with secondary and even third dendrite arms.Correspondingly,the alloy displays different tensile behavior with different processing methods,and the as-deposited specimen shows better ultimate tensile stress(1,085.7±51.7 MPa),yield stress(697±19.5 MPa)and elongation(25.8%±2.2%)than that of the as-cast specimen.The differences in mechanical properties of the alloy are due to the different morphology and size of dendrites,γ’,and Laves phase,and the segregation of elements,etc.Such important information would be helpful for alloy application as well as new alloy development.
基金Funded by the Key Program Project of National Natural Science Foundation of China(NSFC)(No.51641102)Natural Science Foundation of Jiangsu Province(No.16KJB430035)+1 种基金Qing Lan Project of Jiangsu Province in ChinaNational Key Laboratory of Science and Technology on Power Beam Processes of Beijing Aeronautical Manufacturing Technology Research Institute
文摘Low-cycle fatigue behavior of Ni-based superalloy GH586 with laser shock processing(LSP) was investigated. The residual stress of the specimens treated with LSP was assessed by X-ray diffraction method. The microstructure and fracture morphology were characterized by using an optical microscope(OM), a scanning electron microscope(SEM), and a transmission electron microscope(TEM). The results indicated that the maximum residual compressive stress was at about 1 mm from the shocking spot center, where the residual compressive stress was slightly lower. High density tangling dislocations, dislocation walls, and dislocation cells in the microstructure of the specimens treated with LSP effectively prevented fatigue cracks propagation. The fatigue life was roughly twice as long as that of the specimens without LSP. The fatigue crack initiation(FCI) in specimens treated with LSP was observed in the lateral section and the subsurface simultaneously. The fatigue striation in the fracture treated with LSP was narrower than that in the untreated specimens. Moreover, dimples with tear ridges were found in the fatigued zones of the LSP treated specimens, which would be caused by severe plastic deformation.
基金supported by the Ministry of Education,Japan,as Grant-in-Aid for Scientific Research(No.12650072 and 15360046)are greatly acknowledged
文摘An analytical method to investigate the morphological evolution of the cellular mi-crostructure is explored and proposed. The method is essentially based on the Es-helby 's micromechanics theory, and it is extended so as to be applied for a material system containing inclusions with high volume fraction, by employing the average stress field approximation by Mori and Tanaka. The proposed method enables us to discuss a stable shape of precipitate in the material system, which must be influenced by many factors: e.g., volume fraction of precipitate; Young's modulus ratio and lattice misfit between matrix and precipitate; external stress field in multiaxial state; and heterogeneity of plastic strain between matrix and precipitate. A series of numerical calculations were summarized on stable shape maps. The application of the method to predict the γ' rafting in superalloys during creep showed that the heterogeneity of plastic strain between matrix and precipitates may play a significant role in the shape stability of the precipitate. Furthermore, it was shown that the method was successfully applied to estimate the morphology of the cellular microstructure formed in CMSX-4 single crystal Ni-based superalloy.
基金supported by the National Natural Science Foundation of China(Nos.52074228,52305420,and 51875470)the China Postdoctoral Science Foundation(No.2023M742830)the Xi’an Beilin District Science and Technology Planning Project,China(No.GX2349).
文摘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.
基金financial support of the National Natural Science Foundation of China(Nos.52130110 and U22A20189)the Research Fund of the State Key Laboratory of Solidification Processing(No.2023-TS-10)。
文摘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.
文摘Due to their superior combination of heat resistance, high temperature corrosion resistance, toughness and strength, nickel-based superalloys have become of extensive use in the aerospace industry. This research aims to explain why the fatigue life of Inconel-718 in preconditioned samples had larger fatigue lives than pristine samples. The hypothesis is that preconditioning at 700°C and 1.0% strain could lead to thermal activation of the {100} cubic slip plane alongside the {111} octahedral slip plane, potentially improving fatigue life. Using SEM and EBSD imaging, the microstructure of Inconel-718 samples were characterized before and after preconditioning. The directions of the slip bands that formed following the preconditioning were determined. The result was that the existence of both the cubic and octahedral slip systems was confirmed, leading to the thermal activation hypothesized. The existence of both slip planes was considered to be the reason behind the improved fatigue life due to better strain accommodation within the microstructure. It is suggested that focuses for future research includes conducting in-situ observation of slip activation and the application of preconditioning as a manufacturing method.