Search Results (108)

This study systematically investigates the microstructural evolution and mechanical properties of GH2787 superalloy following solution treatment at 1140 °C and subsequent aging within the temperature range of 770 °C to 920 °C. The results indicate that aging at 770 °C and 820 °C promotes the precipitation of a high density of finely dispersed γ′ precipitates with minimal interparticle spacing. In contrast, a significant coarsening of the γ′ particles, accompanied by a sparse distribution and a notable increase in interparticle spacing, was observed at the higher aging temperatures of 870 °C and 920 °C. Mechanical characterization reveals that the ultimate tensile strength (UTS) and yield strength (YS) experienced a moderate decrease as the aging temperature increased from 770 °C to 820 °C, followed by a pronounced drop at 870 °C and 920 °C. Conversely, the impact toughness exhibited a non-monotonic trend: it gradually decreased, reaching a minimum at 820 °C, before rapidly increasing with further rises in aging temperature. Quantitative analysis of the strengthening contributions demonstrates that solid-solution and precipitation strengthening are the dominant mechanisms. The marked decline in yield strength at elevated aging temperatures is primarily attributed to the diminished precipitation strengthening effect due to γ′ coarsening. Furthermore, the variation in impact toughness can be linked to the proportion and size of dimples observed on the fracture surfaces, indicating a transition in the fracture mechanism driven by microstructural evolution. Full article

This study proposes a novel framework for quantifying curved grain boundaries that overcomes key limitations of existing methods. Unlike Fourier-based approaches that require labor-intensive sequential analysis of individual boundaries and selectively represent only high-amplitude regions, or spline-based methods that demand complex parameter selection for interpolation points, the proposed framework integrates curvature variance filtering with U-chord curvature calculation to enable automated, comprehensive, and noise-resistant characterization of grain boundary morphology. The curvature variance filtering adaptively determines smoothing parameters based on local curve properties, while the U-chord curvature method ensures rotational invariance and robustness against digitization errors. Four heat treatment processes were applied to GH4169 alloy, producing distinct grain boundary morphologies with mean curvature (MC) values ranging from 0.0625 to 0.1252. Controlled cooling alone (Process A) yielded predominantly straight boundaries (91.06% straight, 0.12% serrated), while re-dissolution treatment (Process D) produced the highest serration degree (58.81% straight, 3.53% serrated). The quantitative analysis reveals that dispersed δ-phase precipitation creates discrete pinning points, forming serrated boundaries with sharp curvature peaks, whereas dense, parallel δ-phase arrays at specific angles produce coordinated wavy undulations. This framework provides a reliable quantitative tool for optimizing heat treatment protocols to achieve target grain boundary configurations in nickel-based superalloys. Full article

Improved plasticity in superalloy castings minimizes processing defects, reduces stress concentration, and enhances mechanical performance. To obtain the microstructure–plasticity relationship, GH4065A ingots were homogenized at 1140–1200 °C for 5–80 h. Microstructural analysis tracked the evolution of dendritic crystals and precipitates (including η phase, carbides, and borides). Tensile tests were conducted to assess plasticity in terms of elongation and reduction in area. Results show that increasing temperature accelerated dendritic dissolution. While 1140 °C was ineffective for short-term dendrite elimination, temperatures of 1160–1200 °C achieved near-complete dissolution within 30–60 h. Precipitates evolution was also observed: the η phase dissolved preferentially, while the sizes of carbides and borides gradually decreased, especially at 1200 °C. Electron probe microanalysis confirmed Nb as the most segregated element. With higher temperatures, Nb diffused from microsegregated zones toward homogeneity. Plasticity improved notably when the Nb segregation coefficient was ~1.5 but decreased at ~1. The optimal homogenization parameters were determined as 1180 °C for 15–60 h. This study provides key processing guidelines for GH4065A ingots, supporting enhanced service performance and operational safety of related components. Full article

This study introduces a composite method that integrates a diamond-coated tubular grinding electrode with short electric arc machining (SEAM) for GH4099. Mechanical micro-grinding and arc erosion act concurrently within the inter-electrode gap, enabling an in situ “erode–dress” coupling in which the grinding action levels nascent craters and promotes debris evacuation while SEAM supplies localized thermal–electrical energy for removal. A design-of-experiment scheme probes discharge and grinding factors, and performance is evaluated by material removal behavior, electrode wear, and surface integrity. Within a robust window (12–24 V; 500–2000 r/min), the composite process sustains stable discharges without catastrophic melting at 24 V and yields dense, uniform textures. Representative surfaces show controllable areal roughness (Sa ≈ 14–27 µm across 80#–600#), reflecting a practical finishing–efficiency trade-off. Multi-scale characterization (3D topography, cross-sectional metallography, SEM) evidences suppression of recast steps, macro-protrusions, and irregular pits, with more evenly distributed, shallower grinding traces compared to those with single-mode SEAM. The comparative analyses clarify discharge stabilization and recast-layer mitigation mechanisms, establishing a feasible pathway to high-quality, high-efficiency composite SEAM of GH4099 without resorting to overly aggressive electrical conditions. Full article

The present study systematically investigated the hot deformation behavior of GH2787 superalloy within the temperature range of 1060–1120 °C and strain rates of 0.1–10 s⁻¹. An Arrhenius-type constitutive equation was developed that accurately predicts the flow behavior, and the calculated thermal deformation activation energy Q is 364,401.19 J/mol. The hot working map was constructed based on the dynamic material model, which identified two preferred processing regions with power dissipation efficiency exceeding 0.3, and no flow instability was observed across the entire parameter range. Microstructural analysis reveals that the extent of dynamic recrystallization significantly increases with rising temperature and strain rate. Discontinuous dynamic recrystallization (via grain boundary bulging nucleation) serves as the dominant recrystallization mechanism in GH2787 superalloy during hot deformation, while continuous dynamic recrystallization (via subgrain rotation and coalescence) acts as a synergistic auxiliary mechanism, jointly driving microstructural evolution. This study provides important theoretical foundations for optimizing the hot working processes of GH2787 superalloy. Full article

GH2132, an Ni–Cr–Fe-based superalloy for aero-engine components, exhibits hot workability that is highly sensitive to processing parameters. The hot deformation behavior of GH2132 alloy was investigated via isothermal compression (Gleeble-3500-GTC) over 850–1100 °C and 0.001–10 s⁻¹, combined with optical microscopy and EBSD characterization. A strain-compensated Arrhenius-type hyperbolic-sine model was established, achieving high predictive accuracy (R² = 0.9916; AARE = 3.86%) with an average activation energy Q = 446.2 kJ·mol⁻¹. Flow stress decreases with increasing temperature and increases with strain rate, while microstructural softening transitions from dynamic recovery to complete dynamic recrystallization at higher temperatures and lower strain rates. Three-dimensional power-dissipation and hot-processing maps (Dynamic Materials Model) delineate safe domains and instability regions, identifying an optimal window of 1000–1100 °C at 0.001–0.01 s⁻¹ and instability at 850–900 °C with 0.01–0.1 s⁻¹. These results provide guidance for selecting parameters for hot deformation behavior during thermomechanical processing of GH2132. Full article

In order to study the effects of notches on the creep behaviors of GH3230 superalloy, a series of creep tests were conducted on GH3230 superalloy sheets with edge notches at 900 °C and 1000 °C. The creep strain curves and creep life of smooth flat plate specimens were predicted based on the θ parameter method. The results indicated that the second stage of steady-state creep of smooth flat plate specimens dominated the creep process, while the strain rate of notched specimens increased significantly in the third stage. The creep fracture strain gradually decreased with increasing creep load. The creep strain curves obtained based on the θ parameter method were in good agreement with the experimental creep strain curves. The predicted creep life of the smooth flat plate specimens and notch specimens were in good agreement with the experimental results, and all experimental results were within the double dispersion band of the predicted life. Notches exhibited a creep life enhancing effect on GH3230 superalloy under the same net stress level. Both stress concentration factor and the experimental net stress collectively determined the notch life enhancement factor. The higher the experimental net stress, the more pronounced the notch life enhancement effect. Full article

The efficient removal of failed yttria-stabilized zirconia (YSZ) thermal barrier coatings from GH4169 superalloy substrates is crucial for aero-engine maintenance. This study investigates the application of plasma electrolytic technology for YSZ coating removal, systematically examining the effects of key process parameters. Through a three-factor, five-level orthogonal experimental design, the influence of working voltage, solution temperature, and processing time on coating removal effectiveness was analyzed using range analysis. The results demonstrated that solution temperature exerted the most significant effect on coating removal rate, followed by working voltage, with processing time showing the least influence. The optimal parameter combination was determined as 265 V working voltage, 50 °C solution temperature, and 120 s processing time, achieving a maximum coating removal rate of 92.36%. The underlying mechanisms were elucidated through detailed characterization: at 250 V, micro-arc discharge enabled effective coating removal through combined physical bombardment and electrochemical dissolution, while at 300 V, arc discharge caused substrate damage with crater formation. Solution temperature critically affected process stability through its regulation of vapor-gaseous envelope characteristics and current behavior. Verification experiments confirmed that the optimized parameters achieved complete coating removal without substrate damage, preserving surface integrity for subsequent recoating processes. This research provides both theoretical foundation and practical parameters for plasma electrolytic removal of YSZ coatings on hot-section components. Full article

Nickel-based GH3536 alloys prepared by laser powder bed fusion (LPBF) exhibit a mismatch between strength and ductility during the tensile process, which severely restricts their engineering applications in the aerospace field. In order to optimize their performance, this study adopted hot isostatic pressing (HIP) and subsequent heat treatment (HT) to modify the material. The microstructural evolution of the HIP+HT-treated GH3536 alloy during deformation, including grain rotation, grain boundary migration, and dislocation slip transfer behaviors, was systematically investigated at room temperature using in situ tensile experiments. The relationship between the microstructure and mechanical properties was elucidated in greater depth by combining theoretical calculations. The experimental results show that after HIP+HT treatment, the elongation of the alloy increased significantly from 36.5% in the as-built LPBF condition to 45.3 ± 1.6% without a significant reduction in ultimate tensile strength. The plasticity enhancement is mainly attributed to the elimination of defects and the formation of annealing twins. In addition, the formation of substructures inside the grains also delays the fracture of the specimen to some extent. This study is expected to provide a reference for the subsequent optimization of the mechanical properties of alloys via heat treatment processes. Full article

An isothermal hot compression test of GH3230 was carried out under deformation conditions with deformation temperatures ranging from 1020 to 1110 °C and strain rates ranging from 1 to 0.001 s⁻¹. On this basis, the corresponding constitutive equation of the alloy was established. $\dot{\epsilon }=exp\left(36.123\right){\left[sinh\left(0.00587\sigma \right)\right]}^{4.7946}exp\left[-451.507/\left(RT\right)\right]$. At the same time, a power dissipation diagram and thermal processing diagram were created. The peak value η can reach 0.36, and the optimum hot working parameter window of the GH3230 superalloy is 1020~1110 °C/0.1~0.001 s⁻¹. The microstructure evolution of the alloy under different conditions was studied by EBSD. With an increase in deformation temperature and a decrease in strain rate, the grain size significantly improved; the average grain size of the GH3230 alloy increased from 16.86 to 35.06 μm, and the degree of recrystallization of the alloy also improved. The maximum recrystallization volume fraction is 75.2%. At low temperature and high strain rate, the recrystallization mechanism of the microstructure is mainly CDRX, and DDRX is the auxiliary mechanism. At high temperature and low strain rate, the main corresponding recrystallization mechanism gradually transforms into DDRX. Full article

During the machining of nickel-based superalloys using coated tools, a significant amount of cutting heat is generated. This study employs ABAQUS finite element analysis software to establish two-dimensional orthogonal cutting simulation models for three types of coated tools: single-layer AlTiN, double-layer AlTiN/AlCrN, and AlCrN/AlTiN. The research focuses on simulating the cutting temperature and cutting stress of carbide tools with these three different coating types and thicknesses when machining nickel-based superalloy GH4169. The simulation results indicate that the double-layer AlCrN/AlTiN-coated tool exhibits lower maximum cutting temperature and cutting stress on the tool rake face and tool substrate during the cutting process. Compared to the other two coated tools, the cutting temperature and cutting stress on the rake face are reduced by up to 13.2% and 13.3%, respectively. When the AlCrN/AlTiN coating thickness is 2.5 μm with a ratio of 1.5:1, the maximum cutting temperature and cutting stress are minimized. During the cutting process with coated tools, the cutting speed, coating type, and coating thickness significantly influence the maximum cutting temperature and cutting stress. Therefore, investigating the effects of cutting speed, coating type, and coating thickness on carbide-coated tools can reduce tool wear, extend tool life, and thereby improve machining efficiency. Full article

Dissimilar material welding enables the integration of the superior properties of different materials, thereby achieving optimal structural performance and economic efficiency while meeting specific service requirements. The presence of solid-solution strengthening elements such as Ti, Co, and Al, and trace elements such as P and S, in GH3030 nickel-based superalloy leads to their segregation and the formation of intermetallic compounds in the welded joint, resulting in deterioration of joint performance. High-entropy alloys (HEAs), with their high-entropy effect and delayed diffusion effect working synergistically, can effectively suppress compositional segregation caused by uneven elemental diffusion and the formation of intermetallic compounds at interfaces, thereby improving the quality of welded joints and demonstrating great potential for dissimilar material joining. Therefore, in this study, fiber laser welding was used to effectively join AlCoCrFeNi2.1 eutectic high-entropy alloy and GH3030 nickel-based superalloy, with the expectation to improve welded joint element segregation, suppressing the formation of intermetallic compounds, and enhance the welded joint quality and its performance. The AlCoCrFeNi2.1/GH3030 joint exhibits an average yield strength of 1.31 GPa, which is significantly higher than that of the GH3030/GH3030 joint (1.07 GPa). In addition, the AlCoCrFeNi2.1/GH3030 joint shows a higher average work-hardening exponent of 0.337 compared with 0.30 for the GH3030/GH3030 joint, indicating improved plasticity. The results showed that under appropriate welding process parameters, the hardness of the weld zone, transitioning from the nickel-based superalloy to the eutectic high-entropy alloy, exhibited a stable increasing trend, and the joint exhibits good plasticity, with brittle fracture being unlikely. Full article

GH4706 Ni-based superalloy is widely used for aero-engine turbine disks operating below 700 °C, where high-temperature ductility is critical to avoid cracking during die forging and service. However, the microscopic mechanisms by which stabilization treatment regulates its high-temperature ductility remain insufficiently clarified. This study systematically investigated the tensile deformation behavior at a high temperature of 650 °C of the GH4706 Ni-based superalloy after stabilization treatment. Transmission electron microscopy (TEM) and secondary ion mass spectrometry (SIMS) were employed to characterize microstructural evolution and elemental redistribution to clarify the microscopic mechanisms by which stabilization treatment enhanced the high-temperature ductility of the GH4706 alloy. The experimental results indicated that better high-temperature plasticity was obtained, although tensile strength decreased slightly after stabilization. This improvement was mainly attributed to the precipitation of the η phase (Ni₃Ti) and its synergistic interaction with the matrix, which effectively enhanced the plastic deformation capacity of the GH4706 alloy at elevated temperatures. Moreover, η phase precipitation and elemental segregation enhanced grain boundary stability, thus inhibiting crack initiation and delaying necking. SIMS analysis revealed that boron, phosphorus, and sulfur showed significant segregation along grain boundaries during 650 °C tensile testing following stabilization—an effect considered crucial to the observed ductility enhancement. TEM observations further indicated that the interaction between η phase precipitation and the nucleation and evolution of stacking faults during deformation together reduced local stress concentrations and promoted uniform plastic deformation. Full article

Picosecond laser trepanning is a key technology for fabricating film cooling holes in aero-engine turbine blades, overcoming the limitations of conventional machining such as severe tool wear and thermal damage. However, optimizing this advanced process to achieve consistent, high-quality results remains a challenge. This study therefore systematically investigates the influence of key laser parameters (power, scanning speed, defocusing distance, and number of scans) on the geometric quality (diameter, taper, and roundness) of holes trepanned in GH4169 superalloy. The experimental results revealed that laser power and defocusing distance are the dominant factors controlling hole diameter and taper. Furthermore, a critical trade-off was identified concerning the number of scans: while more scans improved exit roundness, they also detrimentally increased entrance diameter and taper due to heat accumulation. Based on these findings, we propose a defect control strategy prioritizing a lower number of scans in the initial phase to effectively suppress molten material formation and preserve surface integrity. This work provides a valuable technological reference and theoretical foundation for the low-damage, high-reliability laser manufacturing of high-performance aerospace components. Full article

To accurately assess the effect of different plate thicknesses on the residual stress field of laser shock peened GH3039 superalloy, residual stress measurements were performed on GH3039 alloy plates with thicknesses of 2 mm and 5 mm after laser shock peening (LSP) treatment. Both quasi-static and high strain rate mechanical tests of GH3039 were conducted, and the Johnson-Cook (J-C) constitutive equation for GH3039 alloy at specific strain rates was fitted based on the experimental results. To obtain the parameter C in the J-C constitutive equation of GH3039 alloy under ultra-high strain rates, a modified method was proposed based on LSP experiment and finite element simulation results. Using the modified GH3039 alloy J-C constitutive equation, numerical simulations and comparative analyses of the residual stress field of GH3039 alloy plates of different thicknesses under LSP were carried out using ABAQUS software. The simulated residual stress fields of laser-shocked GH3039 alloy plates of different thicknesses were in good agreement with the experimental measurements, indicating that the modified GH3039 alloy J-C constitutive equation can accurately predict the mechanical behavior of GH3039 alloy under ultra-high strain rates. Based on the modified GH3039 alloy J-C constitutive equation, the effect of different plate thicknesses on the residual stress distribution of laser-shocked GH3039 alloy was studied, along with the underlying mechanisms. The unique distribution characteristics of residual stresses in laser-shocked GH3039 plates with varying thicknesses are primarily attributed to differences in plate bending stiffness and the detrimental coupling effects of reflected tensile waves. Full article