Search Results (150)

Inconel 617 is a nickel-based superalloy that is a primary candidate for use in next-generation nuclear applications such as the Gen IV Molten Salt Reactor (MSR) and Very-High-Temperature Reactor (VHTR) due to its corrosion and oxidation resistance and high strength in elevated temperatures. However, Inconel 617 machinability is poor due to its hardness and tendency to work harden during manufacturing. While the machinability of its sister grade, Inconel 718, has been widely studied and understood due to its applications in aerospace, there is a lack of knowledge regarding the behaviour of Inconel 617 in machining. To address this gap, this paper investigates the influence of cutting parameters in the turning of Inconel 617 and compares the impact of Minimum Quantity Lubrication (MQL) turning against conventional coolant. This investigation was performed through three distinct studies: Study A compared the performance of commercial coatings, Study B investigated the influence of cutting parameters on the surface finish, and Study C compared the performance of MQL to flood coolant. This work demonstrated that AlTiN coatings performed the best and doubled the tool life of a standard tungsten carbide insert compared to its uncoated form. Additionally, the feed rate had the largest impact on the surface roughness, especially at high feeds, with the best surface quality found at the lowest feed rate of 0.075 mm/rev. The utilization of MQL had mixed results compared to a conventional flood coolant in the machining of Inconel 617. Surface finish was improved as high as 47% under MQL conditions compared to the flood coolant; however, work hardening at the surface was also shown to increase by 10–20%. Understanding this, it is possible that MQL can completely remove the need for a conventional coolant in the machining of Inconel 617 components for the manufacturing of next-generation reactors. Full article

In this work, a crystal plasticity (CP)-based continuum modeling approach is employed to investigate the interaction between dislocations and coherent ${\gamma }^{″}$ precipitates in the Inconel 718 (IN718) superalloy. A finite element (FE) model is developed to accurately represent realistic microstructures in IN718, specifically incorporating a disk-shaped precipitate embedded within a matrix phase. A length-scale-dependent CP modeling simulation informed by molecular dynamics (MD) findings is conducted. The results indicate that the three ${\gamma }^{″}$ variants behave differently under uniaxial loading conditions, altering the deformation process in the $\gamma$ phase and leading to significant strain and stress heterogeneities. The presence of dislocation shearing in the ${\gamma }^{″}$ variants reduces the localization of strain and dislocation densities in the adjacent $\gamma$ phase. The strain gradient-governed geometrically necessary dislocation (GND) density plays a dominant role in influencing strain hardening behavior. The length scale effect is further quantified by considering four different precipitate sizes, with the major axis ranging from 12.5 nm to 100 nm. The findings show that smaller precipitate sizes result in stronger strain hardening, and the size of ${\gamma }^{″}$ precipitates significantly alters GND density evolution. Full article

Nickel-based superalloys are extensively used in high-temperature applications because of their exceptional oxidation and corrosion resistance. However, their performance in aggressive environments containing molten salts, such as Na₂SO₄ and V₂O₅, remains a critical challenge. This study investigated the hot corrosion behavior of Inconel 718, Udimet 710, Nimonic 75, and Inconel 625, focusing on the role of the alloying elements in the corrosion layers and degradation mechanisms. The superalloys were exposed to 50/50 wt.% Na₂SO₄–V₂O₅ at 900 °C for 8, 48, and 96 h, and their corrosion resistance was evaluated through weight gain measurements, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). These results indicate that Mo is a key factor in accelerating degradation, with Inconel 625 exhibiting the highest weight gain owing to the formation of thermally unstable Mo-rich phases. Fe also negatively impacted the stability of the protective scale of Inconel 718, contributing to an increased corrosion rate. In contrast, Nimonic 75 exhibited the best resistance, forming more of the NiCr₂O₄ spinel phase through the reaction of Cr₂O₃ with NiO from the high Ni and Cr contents in the corrosive layers. These findings highlight the importance of alloy composition in optimizing corrosion resistance and suggest that using superalloys with lower Mo and Fe contents and higher Cr and Ni concentrations can significantly enhance the durability of superalloys in molten salt environments. Full article

This paper aims to investigate the effectiveness of cutting fluid during the high-speed face-turning of superalloy Inconel 718 using chamfered whisker-reinforced ceramic inserts. It addresses this topic by providing a comprehensive understanding of the machinability of Inconel 718 under both dry and wet conditions through analytical friction modeling and a detailed analysis of the chip formation process. Two new indexes, named the Area Function (AF) and the Shape Function (SF), were derived to assess the serration intensity of the chips. Particular attention was paid to the interaction between the cutting speed and the cutting fluid. The results showed that wet conditions promote uniform chip formation, more stable forces, a lower coefficient of friction, and the absence of notch wear. At low cutting speed (60 m/min) and dry machining results in high serration intensity (SF = 0.7) and segmentation frequency ($f_{seg}$ = 22.08 kHz) compared to the SF of 0.4 and $f_{seg}$ = 19.69 kHz in wet conditions. The segmentation frequency increases significantly with cutting speed, reaching 71.03 kHz and 63.32 kHz at a cutting speed of 225 m/min for dry and wet conditions, respectively. It was also found that the rate of increase in the tangential force was lower (20.49 N/s) when using cutting fluid at a high cutting speed (225 m/min) compared to dry conditions (27.37 N/s). Full article

Heat-performance nickel-based superalloys are commonly applied in various critical industries. In this work, test samples in the form of turbine blades were manufactured by means of laser powder bed fusion (LPBF) 3D technology. This research focused on comparison of the influences of various surface finishing methods. The mechanical surface post-processing of the LPBF-manufactured Inconel 718 alloy samples consisted of ultrasonic impact treatment (UIT), ultrasonic shot peening (USP), shot peening (SP), and barrel finishing (BF). The surface microrelief was evaluated using a high-precision laser profilometer, while the microstructural features were studied by light optical microscopy (LOM), scanning/transmission electron microscopy (SEM/TEM), and X-ray diffraction (XRD). Potentiodynamic polarization tests were also conducted to compare the surface finishing methods in terms of corrosion resistance improvement of the LPBF-manufactured 718 alloy samples. The effects of the surface microstructure and hardening intensity in combination with residual stresses and surface relief coupled with roughness profile shapes on the room temperature corrosion behavior of plastically deformed 718 alloy specimens manufactured by LPBF were studied. The corrosion rate (CR) of the LPBF-manufactured samples was reduced after post-processing: BF (~16 μm/year), USP (~15 μm/year), SP (~6.5 μm/year), and UIT (~5.5 μm/year). The experimental trends also agreed well with the theoretical trends of uniform corrosion of the studied alloy. Full article

The Inconel 718 alloy is a nickel-based superalloy that can be strengthened through precipitation hardening. Due to its exceptional mechanical properties, high corrosion resistance, and good workability, it is particularly suitable for applications where components operate in corrosive environments at temperatures up to 600 °C. Under these conditions, overheating frequently occurs, leading to structural transformations and changes in mechanical properties. This experimental study examined the effect of repeated overheating on the alloy’s structure, the formation of oxide layers, and hardness. The cyclic overheating process was simulated using thermal shocks induced by solar energy, with temperatures exceeding the recommended range, between 700 and 1000 °C. Morphological characterization, elemental chemical analysis, qualitative phase analysis, and microhardness measurements highlighted the transformations induced by cyclic thermal stress at high temperatures. Full article

This paper presents a comprehensive study of two tool materials designed for the machining of Inconel 718 superalloy, produced through two distinct sintering techniques: High Pressure–High Temperature (HPHT) sintering and Spark Plasma Sintering (SPS). The first composite (marked as BNT), composed of 65 vol% cubic boron nitride (cBN), was sintered from the cBN–TiN–Ti₃SiC₂ system using the HPHT technique at a pressure of 7.7 GPa. The second composite (marked as AZW) was fabricated from the Al₂O₃–ZrO₂–WC system using SPS at a pressure of 63 MPa. The final phase composition of BNT material differed significantly from the initial composition due to reactions occurred during sintering. In contrast, the phase composition of the AZW ceramic composite before and after sintering was similar. The materials exhibited high quality, as evidenced by a Young’s modulus of 580 GPa for BNT and 470 GPa for AZW, along with hardness of 26 GPa for BNT and 21 GPa for AZW. Both composites were used to prepare cutting inserts that were evaluated for their performance in machining Inconel 718 alloy. While both inserts showed durability comparable to their respective reference commercial inserts, they differed in performance and price relative to one another. Full article

The high yttria content of a stabilized zirconia (YSZ) (38 wt% Y₂O₃) coating was deposited by atmospheric plasma spraying (APS) from Metco 207 powders on an Inconel 718 (Ni-based superalloy) substrate. As a metal coating connection, a layer of cermet powder (Ni-20% Al—410NS) was used before the ceramic layer deposition. The electro-chemical corrosion resistance of these materials was tested using Inconel cylinders with a diameter of 10 mm and a thickness of 1 mm, with and without the ceramic layer. Linear and cyclic measurements were obtained in H₂SO₄ electrolyte media at pH = 2. Electro-impedance spectroscopy (EIS) experiments were performed on the sample covered with the ceramic layer to evaluate the interface behavior. Scanning electron microscopy (SEM), along with equipment to determine chemical composition, and an energy dispersive spectrometry (EDS) detector were used to characterize the material surface before and after corrosion tests. It was observed that the corrosion resistance of Inconel was influenced by the bonding layer and the ceramic coating. Full article

Inconel 718 (IN718) is a polycrystalline nickel-based superalloy and one of the most widely used materials in the aerospace industry owing to its excellent mechanical performances at high temperatures, including creep resistance. Interest in additively manufactured components in aerospace is greatly increasing due to their ability to reduce material consumption, to manufacture complex parts, and to produce out-of-equilibrium microstructures, which can be beneficial for mechanical behavior. IN718’s properties are, however, very sensitive to microstructural features, which strongly depend on the manufacturing process and subsequent heat treatments. Additive manufacturing and, more specifically, Laser Powder Bed Fusion (LPBF) induces very high thermal gradients and anisotropic features due to its inherently directional nature, which largely defines the microstructure of the alloy. Hence, defining appropriate manufacturing parameters and heat treatments is critical to obtain appropriate mechanical behavior. This review aims to present the main microstructural features of IN718 produced by LPBF, the creep mechanisms taking place, the optimal microstructure for creep strength, and the most efficient heat treatments to yield such an optimized microstructure. Full article

High energy density technologies for welding processes provide opportune solutions to joint metal materials and repair components in several industrial applications. Their high-performance levels are related to the high penetration depth and welding speed achievable. Moreover, the localized thermal input helps in reducing distortion and residual stresses in the welds, minimizing the extension of the fusion zone and heat-affected zone. The use of these welding technologies can be decisive in the employment of sophisticated alloys such as Ni-based superalloys, which are notoriously excellent candidates for industrial components subjected to high temperatures and corrosive work conditions. Nonetheless, the peculiar crystallographic and chemical complexity of Ni-based superalloys (whether characterized by polycrystalline, directionally solidified, or single-crystal microstructure) leads to high susceptibility to welding processes and, in general, challenging issues related to the microstructural features of the welded joints. The present review highlights the advantages and drawbacks of high energy density (Laser Beam and Electron Beam) welding techniques applied to Ni-based superalloy. The effects of process parameters on cracking susceptibility have been analyzed to better understand the correlation between them and the microstructure-mechanical properties of the welds. The weldability of three different polycrystalline Ni superalloys, one solid solution-strengthened alloy, Inconel 625, and two precipitation-strengthen alloys, Nimonic 263 and Inconel 718, is reviewed in detail. In addition, a variant of the latter, the AF955 alloy, is also presented for its great potential in terms of weldability. Full article

In order to improve the anti-friction property of common mineral oil and develop a high-performance lubricant, MoS₂ and SiO₂ nano-additives were individually dispersed into the 350SN mineral oil at various weight percentages to prepare nanolubricants. Then, the viscosity, wettability, and tribological properties of the nanolubricants were measured and analyzed with a rotary viscometer, a contact angle measuring instrument, and a friction tester. Finally, the action mechanism of two nano-additives was explained based on the energy spectrum test results of the abrasion surface. The results show that MoS₂ and SiO₂ nano-additives could improve the viscosity of the base fluid and change its wettability, giving nanolubricants better anti-friction performance than the base fluid. Due to the difference in physical properties, SiO₂ and MoS₂ nanolubricants presented different friction reduction rules with the increase in nano-additive percentage. Under experimental conditions, SiO₂ nanolubricants showed better anti-friction effects than MoS₂ nanolubricants. When the SiO₂ percentage was 10 wt% and 15 wt%, the maximum friction coefficient was reduced to 0.06, which was about 1/3 of that with the base fluid. In this case, the abrasion surface quality was significantly improved, and the abrasion trace size was about half that of the base fluid. The energy spectrum test results show that the action mechanism of the MoS₂ nano-additive is the adsorption film effect and mending effect of nanoparticles, while the main action mechanism of the SiO₂ nano-additive should be the polishing effect and rolling effect of nanoparticles. Full article

The aviation industry is still looking for effective manufacturing methods. Currently, the challenge is still the machining of shapes in thin-walled materials. This work focuses on the analysis of the influence of these parameters on deformations during the drilling process of holes in the adapters of aircraft engine body accessories. The drilling process was carried out in the thin-walled superalloy Inconel 718, which is classified as a difficult-to-machine material. During the analyses, experimental studies based on the Response Surface Method (RSM) and finite element method (FEM) calculations were carried out simultaneously. The aim of this work was to analyze the developed mathematical models describing nonlinear relationships between cutting parameters, cutting forces, and deformations of the aircraft engine body characterized by a complex, thin-walled geometric structure. By using the proposed solutions, it is possible to achieve integration between the techniques of conducting research, performing calculations using FEM, and designing the machining. The advantage of this comprehensive approach used in our work is the development of mathematical models that strongly fit the results of the research. The results of analyses and calculations presented in the article and the research methodology used can be applied to industrial conditions. Full article

Material wear, maintenance costs, performance, efficiency, and corrosion are some of the issues that turbomachinery impellers may encounter. The optimization of impellers through additive manufacturing (AM) has been the focus of extensive research, aiming to address these challenges in turbine, pump, compressor, fan, and mixer components. This research aims to identify and analyze the main techniques currently being developed to tackle several of these issues. Evaluating the published research, the methodology highlights various AM techniques applied to impellers and related components, as well as the diverse materials used in functional system elements. The analysis revealed that the most commonly used additive manufacturing technologies for the production of turbomachinery components are FDM, with a 22% application rate, and powder bed fusion technology, accounting for 35%, utilized for high-complexity parts and even superalloys. Although more expensive, these technologies employ materials with superior resistance capabilities, surpass the limitations of conventional machining, optimize manufacturing times, and allow for the fine-tuning of multiple parameters. In terms of wear and corrosion resistance, materials such as Inconel 718 exhibited a loss of less than 0.1 mpy (mils per year) in highly corrosive environments, representing a significant improvement over traditional materials. 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

The Inconel 718 superalloy, a precipitation-hardenable material, is of particular interest for applications involving components operating under extreme conditions due to its excellent mechanical properties, high corrosion resistance at temperatures up to 700 °C, and good workability. At high temperatures, thermal transfer processes are crucial for temperature distribution across the component’s section, structural transformations, and variations in the alloy’s properties. The history of accidental overheating events is critical for the microstructure and properties of the alloy. Studies on thermal transfer in the Inconel 718 alloy available in the literature typically focus on the alloy in its as-delivered state. The experimental research presented in this paper examines the influence of repeated overheating history on the thermal diffusivity of the alloy. Full article