Search Results (1,147)

The plasma immersion nitriding system was utilized to make massive nitrogen supersaturation (MNS) to CoCrMo disc and die substrates at 723 K for 21.6 ks. The top layer thickness in the multi-layered MNSed layer was 20 μm. Its nitrogen solute content reached 5 mass% on average after SEM-EDX analysis. The surface hardness was 1300 HV_1N (HV_0.1), which was much higher than the bare CoCrMo with 450 HV_1N. The original polycrystalline structure was modified to be a multi-layered microstructure, which consisted of the nanograined MNSed top layer, the buffer layer with a thickness of 5 μm, and the column–granular structured layer with their textured crystallographic orientations. The BOD (ball-on-disc) testing was employed to describe the frictional sliding behavior under the applied loads of 5 N and 10 N and the sliding velocity of 0.1 m/s against the AISI316 ball. The friction coefficient was held constant by 0.68 on average. The CNC (Computer Numerical Control) stamping system was employed to upset the fine-grained 1.0 mm thick AISI316 wire up to 70% in reduction in thickness. The friction coefficient at RT was estimated to be 0.05. A round, fine-grained AISI316 wire was shaped into a thin plate with a thickness of 0.3 mm in cold and dry. Full article

The deformation and damage mechanisms of a single crystal nickel-based superalloy containing 6.0%Re/5.0%Ru were studied through creep performance tests at 800 °C/860–880 MPa, microstructure and morphology observation, and dislocation configuration analyzation. It was found that, during the creep process at the intermediate temperature, the γ′ phase does not form a raft-like structure. After a creep fracture, the distortion degree of the cubic γ′ phase becomes greater when the observation region is closer to the fracture. The alloy has a long creep life at 800 °C, and the dislocation slipping or climbing in the γ matrix is the deformation mechanism at the early and middle creep stages. At the later creep stage, the γ′ phase is sheared by dislocations. Because of the low stacking-fault energy of the alloy, the <110> superdislocation shearing into the γ′ phase can decompose on the {111} plane to form a (1/3) <112> partial dislocation and stacking-fault configuration or cross-slip to the {100} plane to form the Kear–Wilsdorf (K-W) lock, which greatly improves the creep resistance of the alloy. At the later creep stage, the primary/secondary slip systems in the alloy are activated alternately, resulting in micro-cracks at the intersection of the two slip systems. As the creep progresses, the initiated cracks spread and propagate in the γ matrix phase along a direction normal to the stress axis and connect with each other until creep fracture occurs. This is the fracture mechanism of the alloy during creep at the medium temperature. Full article

Large TiN inclusions in nickel-based superalloys promote micropore formation, compromising the mechanical properties of the alloys. However, current research lacks a comprehensive coupled model that considers both solute element microsegregation and TiN precipitation specifically in nickel-based superalloys. This study investigated TiN precipitation during the solidification of IN718 alloys through a combined thermodynamic and kinetic approach. A modified Clyne–Kurz model was applied to account for multi-element microsegregation, enabling an integrated analysis of both microsegregation and precipitation processes. The results indicated that solute elements in the molten alloy segregated to varying degrees during solidification. At an initial nitrogen concentration of 25 ppm, TiN inclusions precipitated when the solid fraction reached 0.256, eventually resulting in a total TiN precipitation of 64 ppm by the end of solidification, while residual nitrogen in the liquid phase decreased to 1.3 ppm. Increasing the initial nitrogen concentration from 10 ppm to 40 ppm advanced the onset of TiN precipitation and raised the total amount from 16 ppm to 126 ppm. Further analysis indicated that cooling rates of 0.03 °C/s, 0.06 °C/s, and 0.18 °C/s did not significantly affect the final TiN accumulation. Full article

Refractory superalloys (RSAs) are promising candidates for high-temperature, high-strength applications. Two-phase RSAs containing body-centered cubic (BCC) and ordered B2 phases are among the more promising candidates. Systems containing Ru-based B2 precipitates exhibit stable two-phase microstructures at temperatures in excess of 1600 °C. The present study experimentally investigated one potential foundational ternary system for these alloys, Nb-Ti-Ru. Two alloys, (Nb₃Ti)_0.85Ru_0.15 and (Nb₄Ti)_0.85Ru_0.15, were studied to determine phase equilibria and properties at temperatures between 900 °C and 1300 °C. The B2 phase was found to be dominated by RuTi ordering, although considerable Nb solubility was observed up to 18 mol %. The Nb-rich BCC matrix contained up to 15 mol % Ru and 20 mol % Ti. Although a two-phase microstructure of B2 precipitates in a BCC matrix was confirmed, the distribution of elements in the two phases resulted in a larger lattice misfit than expected. The results obtained in this investigation provide valuable information for the future development of RSAs utilizing Ru-based B2 strengthening precipitates. Full article

Inconel 718 is a widely popular aerospace superalloy known for its high-temperature performance and resistance to oxidation, creep, and corrosion. Traditional manufacturing methods, like casting and powder metallurgy, face challenges with intricate shapes that can result in porosity and uniformity issues. On the other hand, Additive Manufacturing (AM) techniques such as Powder Bed Fusion (PBF) and Direct Energy Deposition (DED) can allow the creation of intricate single-part components to reduce weight and maintain structural integrity. However, AM parts often exhibit directional solidification, leading to anisotropic properties and potential crack propagation sites. To address this, post-processing treatments like HIP and heat treatment are necessary. This study explores the effects of the raster and stochastic spot melt scanning strategies on the microstructural and mechanical properties of IN718 parts fabricated using Electron Beam Powder Bed Fusion (EB-PBF). This research demonstrates that raster scanning produces columnar grains with higher mean aspect ratios. Stochastic spot melt scanning facilitates the formation of equiaxed grains, which enhances microstructural refinement and lowers anisotropy. The highest microstructural values were recorded in the raster-produced columnar grain structure. Conversely, the stochastic melt-produced transition from columnar to equiaxed grain structure demonstrated increased hardness with decreasing grain size; however, the hardness of the smallest equiaxed grain structure was slightly less than that of the columnar grain structure. These findings underscore the vital importance of scanning strategies in optimizing the EB-PBF process to enhance material properties. Full article

This work focuses on the effects of ultrasonic shot peening (USP) on grain refinement and orientation behavior in the surface region of GH4151 superalloy. The microstructure evolution of the alloy under USP durations were studied. The effects of USP-induced grain refinement, orientation, and dislocation motion behavior were analyzed. The results indicated that during the USP process, the plastic deformation of the surface layer of superalloys is accompanied by changes in grain size and orientation. The random impact of the spheres on the surface area promotes grain refinement and grain rotation, enhancing the randomness of grain orientations and reducing the texture strength and the proportion of “soft” orientation distribution. Over a long period of treatment, a large number of spheres cause the slip planes and slip directions of each grain to rotate due to the additional shear stress from the impact, resulting in relatively consistent plastic deformation on the surface and the enhanced randomness of grain orientations, thus reducing the high texture strength introduced by previous machining processes. The understanding of dislocation pile-up behavior and the relationship between externally applied shear stress, pile-up characteristics, and grain refinement is essential for optimizing the USP process and achieving the desired material properties. Full article

High-speed ballistic impact tests were conducted at room temperature and 500 °C on nickel-based superalloy GH4169 simulated blade specimens containing leading-edge features. The microscopic characteristics of the impact notch at room temperature versus 500 °C were observed by electron backscatter diffraction (EBSD), and it was found that the grains on the notched subsurface were ruined, while in more distant regions, the impact energy was mainly absorbed by grain boundaries. Internal damage is more concentrated in the notched subsurface region at 500 °C compared to room temperature. The high cycle fatigue strength of the damaged specimens under different conditions was tested. The results showed that the high cycle fatigue strength of the damaged specimens increased with the increase in the notch depth, and the fatigue strength of the damaged specimens at 500 °C was higher than the fatigue strength at room temperature. Both the 48 h post-impact holding time at 500 °C and the preload during impact at 500 °C increased the fatigue strength of the damaged specimens. Full article

Friction and high temperatures greatly affect the hardness and processing efficiency of superalloys. Therefore, it is important to provide a coating on their surfaces with a hard layer. In this study, pack boronizing was applied on Inconel 601 to improve its microstructure and tribological properties. In this regard, tribological tests were performed under MQL, nano-MQL1 (MQL + CuO), and nano-MQL2 (MQL + TiO₂) environments. The research results showed that the lowest wear depth, friction force, coefficient of friction (CoF), and volume loss values were obtained in pack-boronized Inconel 601 in a nano-MQL2 environment. In the nano-MQL2 environment, the wear depth decreased by 17.81% (from 57.922 µm to 47.605 µm) with package-boronized Inconel 601 compared to as-received Inconel 601 at a 45 N load. Pack-boronized Inconel 601 experienced an average reduction of 30.23%, 41.60%, and 52.32% in friction force when switching from dry to MQL, nano-MQL1, and nano-MQL2 environments, respectively. It was also observed that the coefficient of friction (CoF) and volume loss values decreased with pack boronizing in an MQL/nano-MQL environment. In a nano-MQL2 environment at 15 N load, volume losses for as-received and boron-coated Inconel 601 were determined as 0.288 mm³ and 0.249 mm³, respectively (13.54% decrease). The findings of this study demonstrate that pack boronizing and MQL and nano-MQL techniques enhance the tribological characteristics of Inconel 601 alloys. Full article

Grit particles remaining on the substrate surface after grit blasting are generally considered to impair the thermal performance of thermal barrier coatings (TBCs). However, the specific mechanisms by which these particles degrade the multilayer structure of TBCs during thermal cycling have not yet been fully elucidated. In this study, the superalloy substrate was grit-blasted using various processing parameters, followed by the deposition of thermal barrier coatings (TBCs) consisting of a metallic bond coat (BC) and a ceramic top coat (TC). After thermal shock tests, local thinning or discontinuities in the thermally grown oxide (TGO) layer were observed in TBCs where large grit particles were embedded at the BC/substrate interface. Moreover, cracks originated at the concave positions of the TGO layer and propagated vertically towards BC; these cracks may be associated with additional stress imposed by the foreign grit particles during thermal cycling. At the BC/substrate interface, crack origins were observed in the vicinity of large grit particles (~50 μm). Full article

GH4169 alloy, a nickel-based superalloy known for its excellent high temperature resistance, corrosion resistance, mechanical properties, and high-temperature tribological properties, is widely used in industrial applications, such as in gas turbines for space shuttles and rocket engines. This study addresses the issue of electrolyte product residue in the electrochemical machining process of a GH4169 alloy by utilizing a C₆H₅Na₃O₇-containing NaNO₃ new mixed electrolyte. Comparative investigations of the electrochemical behavior and electrolyte product removal mechanisms at different concentrations of C₆H₅Na₃O₇ additive in NaNO₃ solutions were conducted. The effects of additives, applied voltage, and the rotating speed of the cathode tool on the processing performance of micro-pit arrays on a GH4169 alloy were analyzed. The results indicate that the mixed solution containing C₆H₅Na₃O₇ significantly improves the localization and geometric morphology of the micro-pits compared to a single NaNO₃ solution. The optimal electrochemical machining parameters were identified as 0.5 wt% C₆H₅Na₃O₇ + 10 wt% NaNO₃ mixed electrolyte, 12 V applied voltage, and 0.1 r/min rotating speed of the cathode tool. Under these conditions, high-quality micro-pit arrays with an average diameter of 405.85 μm, an average depth of 87.5 μm, and an etch factor (EF) of 1.67 were successfully fabricated, exhibiting excellent morphology, localization, and consistency. Full article

Hot isostatic pressing (HIP) is a near-net shape powder metallurgy (PM) technique, which has emerged as an efficient technique, offering precise control over the microstructure and properties of materials, particularly in high-performance alloys. This technology finds applications across a wide range of industries, such as aerospace, automotive, marine, oil and gas, medical, and tooling. This paper provides an overview of powder metallurgy and hot isostatic pressing, covering their principles, process parameters, and applications. Additionally, it conducts an analysis of PM-HIPed alloys, focusing on their microstructure and fatigue behavior to illustrate their potential in diverse engineering applications. Specifically, this paper focuses on nickel-based superalloys and martensitic tool steels. The diverse microstructural characteristics of these alloys provide valuable insights into the PM-HIP-induced fatigue defects and properties. Full article

Melting point depressants (MPDs) are required to lower the melting point of filler for brazing. In this study, Zr was used as the MPD, and powder filler was prepared by adjusting the Zr and Mo content referring to Thermo-Calc calculations. The prepared filler was used to braze a high-Mo Ni₃Al-based single crystal superalloy, IC21, for 1200 °C/30 min. The effects of adjusting the Zr and Mo content on the microstructure and tensile properties of the joint were investigated. The increase in Zr content promotes the formation of Ni₇Zr₂ in the joint, leading to a decrease in the tensile strength of the joint. The increase in Mo content forms diffusion barriers between the BM and filler, resulting in an enhancement in the tensile strength of the joint. However, continued increases in Mo content leads to an increase in the P-topologically close packed phase, causing a decline in the tensile strength of the joint. When the Zr content was (11.8–12.2) wt.% and the Mo content was (7.3–7.7) wt.%, the tensile strength of the joint at 980 °C reached a maximum of 550 MPa. This study provides a potential direction for the design of brazing filler composition for high-Mo Ni₃Al-based superalloys. Full article

As a crucial high-performance material, nickel-based superalloys inevitably generate residual stresses during processing, manufacturing, and usage. The mechanical properties of nickel-based superalloys are significantly reduced by residual stress, which becomes one of the important factors restricting material reliability. The systematic analysis of residual stresses in nickel-based superalloys throughout the entire manufacturing and usage processes is insufficient. The residual stress generation factors, measurement methods, prediction models, and control methods in nickel-based superalloys in recent years are summarized in this paper. The current challenge and future development trends in the research process of nickel-based superalloy residual stress are also presented. A theoretical reference for further research on residual stresses in nickel-based superalloys can be provided in this review. Full article

Complex oxide–carbonitrides (MgO-Ti(CN), Al₂O₃-Ti(CN), and MgO·Al₂O₃-Ti(CN)) are the most common non-metallic inclusions presented in cast and wrought superalloys. In this work, a coupled kinetics model was proposed to predict the complex oxide–carbonitride inclusion’s precipitation behavior during the solidification of superalloys. This model takes into account thermodynamics, micro-segregation, heterogeneous nucleation in the inter-dendritic liquid, and growth controlled by the diffusion of solute elements and kinetics of interfacial reaction. The results demonstrated that both the cooling rate and nitrogen content take significant effects on the final size of complex oxide–carbonitride inclusions, as the former controls the total growth time and the latter determines the initial precipitation temperature. In comparison, the particle size of primary oxides shows a negligible impact on the final size of complex inclusions. The practice of an industrial vacuum arc remelting confirmed that the inclusion size variation predicted by the present model is reasonably consistent with the experimental results. Full article