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1 – 10 of 134Xinmei Wang, Yao Wang and Xinzhong Wang
Specimen thickness has great influences on the creep behavior of single crystal Ni-based superalloys when it is less than 3.0 mm, which is known as thickness debit effect…
Abstract
Purpose
Specimen thickness has great influences on the creep behavior of single crystal Ni-based superalloys when it is less than 3.0 mm, which is known as thickness debit effect. Experiments have detected that oxidation can influence the microstructure of the Ni-based superalloys. Here, a model is proposed to bring in both the oxidation effect and void caused damage to account for the thickness debit effect. The paper aims to discuss these issues.
Design/methodology/approach
The model uses the simple Norton type creep relation to describe the creep rate evolution. The damage evolution caused by void is taken to be stress controlled. The load baring area changes are calculated with the consideration of oxidation and void evolutions.
Findings
Simulations on specimens with different thickness from 3.0 to 0.3 mm are carried out. The results show that the present model can reproduce the decrease of the creep strength with the decreases of the specimen thickness. The damage plays a major role in the creep behavior of the thick specimen. Both the damage and the oxidation are important for the thin specimen which should be paid attention to during the calculation of the creep response of the thin-wall turbine blade.
Originality/value
A model is proposed to account for the thickness debit effect on the creep behavior of Ni-based superalloys. Both oxidation influence and void caused damage are introduced. The simulation results show the capability of the model to reproduce the thickness debit effect.
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Liu Junyan, Han Rongdi and Wang Yang
Green machining is becoming increasingly more popular due to concern regarding the safety of the environment and human health. The important implementation of stricter…
Abstract
Purpose
Green machining is becoming increasingly more popular due to concern regarding the safety of the environment and human health. The important implementation of stricter Environmental Protection Agency regulations associated with the use of ample amount of coolants and lubricants has led to this study on a new green machining technology with application of water vapor as coolants and lubricants in cutting Ni‐based superalloys and titanium alloy Ti‐6Al‐4V with uncoated carbide inserts (ISO Type K10). The purpose of this paper is to show that machining technology with application of water vapour could be an economical and environmentally compatible lubrication technique for machining difficult‐cut‐materials.
Design/methodology/approach
In this paper, the effect of water vapor applications in machining difficult‐cut‐materials have been investigated in detail, the cutting force, the chip deformation coefficient, the rake face wear and the width of tool flank land VB have been examined and analyzed, and a new green cutting technology is researched to machining Ni base superalloys and Ti‐6Al‐4V difficult‐cut‐materials.
Findings
The cutting force of machining Ni base superalloys and Ti‐6Al‐4V was affected by direct water vapor application, being lower than dry cutting and wet machining for all machining conditions; the Λh is the smallest with applications of water vapor as coolants and lubricants compared to dry cutting, pure water and oil water emulsion conditions the tool life extended by about six times than dry cutting, about four times than oil water emulsions at low cutting speed (νc<100 m/min), and about two‐four times than dry cutting, about two‐three time than oil water emulsions at higher cutting speed (νc>100 m/min) during machining Ti‐6Al‐4V with application of water vapor direct into the cutting zone.
Originality/value
The green cutting technology which applies water vapor as coolants and lubricants advocates a new method for machining difficult‐cut‐materials (Ni base superalloys and Ti‐6Al‐4V) without any environment pollution and operator health problem because the cutting force and chip deformation coefficient are reduced, the tool life is extended, and the tool flank wear can be decreased with applications of water vapor as coolants and lubricants to alleviate the adhering and diffusion wear compared to wet cutting and dry cutting.
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Saib Cherif and Boumerzoug Zakaria
The Ni-base superalloy INC738LC is a precipitation strengthened alloy and is widely used in hot sections of gas turbine engines owing to its excellent high-temperature strength…
Abstract
Purpose
The Ni-base superalloy INC738LC is a precipitation strengthened alloy and is widely used in hot sections of gas turbine engines owing to its excellent high-temperature strength and high hot corrosion resistance. The purpose of this study is to determine the appropriate welding current of Ni-base superalloy INC738LC after two passes of applying the tungsten inert gas (TIG) welding technique.
Design/methodology/approach
Ni-base superalloy INC738LC plates were joined by TIG welding technique by varying the welding current (30, 40 and 50 A). Welded specimens were investigated using optical microscopy, tensile tests, Vickers’s micro-hardness tests and X-ray diffraction (XRD). Optical microscopy was used to characterize fusion zone, heat-affected zone and base metal. Tensile test was conducted to characterize weld strength by determining ultimate tensile strength. Scanning electron microscopy was used to investigate the fracture surfaces after tensile tests. Micro-hardness test was conducted to characterize the welded joint. XRD was applied to determine precipitates formed after welding.
Findings
The ultimate tensile strength results show that the optimum weld current out of the three weld currents was found to be 40 A, which is the closest to that of the base metal.
Originality/value
Many researchers have worked to optimize welding parameters such as current and speed from the microstructural observations and mechanical properties of welded joints. The optimum weld current out of the three weld currents was found to be 40 A.
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H. Singh, D. Puri, S. Prakash and M. Srinivas
To characterise the high temperature oxide scales for some plasma sprayed NiCrAlY coated Ni‐ and Fe‐based superalloys.
Abstract
Purpose
To characterise the high temperature oxide scales for some plasma sprayed NiCrAlY coated Ni‐ and Fe‐based superalloys.
Design/methodology/approach
Ni‐22Cr‐10Al‐1Y metallic coatings were deposited on two Ni‐based superalloys; Superni 601 and Superni 718 and one Fe‐based superalloy; Superfer 800H by the shrouded plasma spray process. Oxidation studies were conducted on uncoated as well as plasma spray coated superalloys in air at 900°C under cyclic conditions for 50 cycles. Each cycle consisted of 1 h heating followed by 20 min of cooling in air. The thermogravimetric technique was used to approximate the kinetics of oxidation. X‐ray diffraction, SEM/EDAX and EPMA techniques were used to analyse the oxide scales.
Findings
All of the coated, as well as the uncoated, superalloys followed an alnost‐parabolic rate of oxidation. The NiCrAlY coating was found to be successful in maintaining its continuous contact with the superalloy substrates in all the cases. The oxide scales formed on the exposed NiCrAlY coated superalloys were found to be intact and spallation‐free. The main phases analysed for the coated superalloys were oxides of nickel, chromium and aluminium and spinel of nickel and chromium, which are expected to be useful for developing oxidation resistance at high temperatures.
Practical implications
The coated superalloys showed remarkable cyclic oxidation resistance under simulated laboratory conditions. However, it is suggested that these coated superalloys also should be tested in actual industrial environments of boilers and gas turbines, etc. so as to obtain more practical and reliable oxidation data.
Originality/value
The knowledge of the reaction kinetics and the nature of the surface oxide scales formed during oxidation is important for evaluating the alloys for their use and degradation characteristics in high temperature applications such as steam boilers, furnace equipment, heat exchangers and piping in chemical industry, reformer, baffle plates/tubes in fertilizer plants, jet engines, pump bodies and parts.
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Hairui Jiang, Jianjun Guan, Yan Zhao, Yanhong Yang and Jinglong Qu
The purpose of this study is to investigate the corrosion resistance of superalloys subjected to ultrasonic impact treatment (UIT). The passive film growth on the superalloys’…
Abstract
Purpose
The purpose of this study is to investigate the corrosion resistance of superalloys subjected to ultrasonic impact treatment (UIT). The passive film growth on the superalloys’ surface is analyzed to illustrate the corrosion mechanism.
Design/methodology/approach
Electrochemical tests were used to investigated the corrosion resistance of GH4738 superalloys with different UIT densities. The microstructure was compared before and after the corrosion tests. The passive film characterization was described by electrochemical impedance spectroscopy (EIS) and X-ray photoelectron spectroscopy (XPS) tests.
Findings
The compressive residual stress and corrosion resistance of the specimens significantly increased after UIT. The order of corrosion resistance is related to the UIT densities, i.e. 1.96 s/mm2 > 1.71 s/mm2 > 0.98 s/mm2 > as-cast. The predominant constituents of the passive films are TiO2, Cr2O3, MoO3 and NiO. The passive film on the specimen with 1.96 s/mm2 UIT density has the highest volume fraction of Cr2O3 and MoO3, which is the main reason for its superior corrosion resistance.
Originality/value
This study provides quantitative corrosion data for GH4738 superalloys treated by ultrasonic impact. The corrosion mechanism is explained by the passive film’s characterization.
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Fanjie Zhou, Chunmei Ma, Yuheng Zhang, Jialu Wang and Huadong Fu
This study aims to control the oxidation resistance of Co-based deformed superalloys by adding trace elements Hf and Si.
Abstract
Purpose
This study aims to control the oxidation resistance of Co-based deformed superalloys by adding trace elements Hf and Si.
Design/methodology/approach
The effects and mechanism of trace elements Hf and Si on the oxidation behavior of Co-Ni-Al-W-based forged superalloys were investigated by cyclic oxidation at 900°C.
Findings
The results show that the addition of trace elements Hf and Si does not affect the type of surface oxides of Co-Ni-based superalloys, and the oxidation layers of the alloys are TiO2, spinel, Cr2O3, TaTiO4, Al2O3 and TiN from outside to inside. However, the addition of elements can affect the activity of Cr and Ti elements; decrease the formation of TiO2 and TaTiO4 layers, which are harmful to the oxidation performance; and then improve the oxidation resistance of the alloy.
Originality/value
The relevant research results can not only optimize the microalloying element content of Co-Ni-Al-W-based superalloys, but also provide a new perspective for the composition optimization design of superalloys.
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Modupeola Dada, Patricia Popoola and Ntombi Mathe
This study aims to review the recent advancements in high entropy alloys (HEAs) called high entropy materials, including high entropy superalloys which are current potential…
Abstract
Purpose
This study aims to review the recent advancements in high entropy alloys (HEAs) called high entropy materials, including high entropy superalloys which are current potential alternatives to nickel superalloys for gas turbine applications. Understandings of the laser surface modification techniques of the HEA are discussed whilst future recommendations and remedies to manufacturing challenges via laser are outlined.
Design/methodology/approach
Materials used for high-pressure gas turbine engine applications must be able to withstand severe environmentally induced degradation, mechanical, thermal loads and general extreme conditions caused by hot corrosive gases, high-temperature oxidation and stress. Over the years, Nickel-based superalloys with elevated temperature rupture and creep resistance, excellent lifetime expectancy and solution strengthening L12 and γ´ precipitate used for turbine engine applications. However, the superalloy’s density, low creep strength, poor thermal conductivity, difficulty in machining and low fatigue resistance demands the innovation of new advanced materials.
Findings
HEAs is one of the most frequently investigated advanced materials, attributed to their configurational complexity and properties reported to exceed conventional materials. Thus, owing to their characteristic feature of the high entropy effect, several other materials have emerged to become potential solutions for several functional and structural applications in the aerospace industry. In a previous study, research contributions show that defects are associated with conventional manufacturing processes of HEAs; therefore, this study investigates new advances in the laser-based manufacturing and surface modification techniques of HEA.
Research limitations/implications
The AlxCoCrCuFeNi HEA system, particularly the Al0.5CoCrCuFeNi HEA has been extensively studied, attributed to its mechanical and physical properties exceeding that of pure metals for aerospace turbine engine applications and the advances in the fabrication and surface modification processes of the alloy was outlined to show the latest developments focusing only on laser-based manufacturing processing due to its many advantages.
Originality/value
It is evident that high entropy materials are a potential innovative alternative to conventional superalloys for turbine engine applications via laser additive manufacturing.
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Nataliya Perevoshchikova, Jordan Rigaud, Yu Sha, Martin Heilmaier, Barrie Finnin, Elena Labelle and Xinhua Wu
The Ni-based superalloy IN-738 LC is known to be susceptible to porosity and different types of cracking during the build-up process and, thus, challenging to manufacture using…
Abstract
Purpose
The Ni-based superalloy IN-738 LC is known to be susceptible to porosity and different types of cracking during the build-up process and, thus, challenging to manufacture using selective laser melting (SLM). Determining a feasible set of operating parameters for SLM of nickel-based superalloys involves new approach to experimental design based on the Doehlert method that assists in determining an optimal (feasible) set of operating parameters for SLM of IN-738 LC powder alloy.
Design/methodology/approach
The SLM parameters are evaluated in terms of their effectiveness in obtaining the microstructure with a porosity content of <0.5 per cent and without micro-cracking. The experimental approach is exemplified with the Doehlert matrix response variable, relative density, by comparing Archimedes method with microstructural assessments of pores and cracks from image analysis. The effect of heat treatment (HT) and hot isostatic pressing (HIP) on the microstructure of the SLMed IN-738 LC powder alloy has been examined and the consequential tensile response characterised.
Findings
By using optimised process parameters (low heat input, medium scanning speed and small hatching distance) which provides medium energy density, samples of IN-738 LC with a macroscopic porosity <0.5 per cent and free of micro-cracks can be manufactured by SLM. The results indicate that HIP of SLMed material did not lead to a noticeable effect on mechanical properties compared to HT of SLMed material suggesting that the level of both porosity and crack density might be already below the detection limit for the mere heat-treated material.
Originality/value
SLM processing parameters (power, scan speed, hatching distance) for IN-738 LC were successfully optimised after only 14 experiments using Doehlert design. Two independent methods, Archimedes method and image analysis, were used in this study to assess relative density of SLM-produced samples with sets of processing parameters showing coherency in prediction with predicted response by Doehlert design.
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Ferhat Ceritbinmez and Ali Günen
This study aims to comparatively analyze the cut parts obtained as a result of cutting the Ni-based Inconel 625 alloy, which is widely used in the aerospace industry, with the…
Abstract
Purpose
This study aims to comparatively analyze the cut parts obtained as a result of cutting the Ni-based Inconel 625 alloy, which is widely used in the aerospace industry, with the wire electro-discharge machining (WEDM) and abrasive water jet machining (AWJM) methods in terms of macro- and microanalyses.
Design/methodology/approach
In this study, calipers, Mitutoyo SJ-210, Nikon SMZ 745 T, scanning electron microscope and energy dispersive X-ray were used to determine kerf, surface roughness and macro- and microanalyses.
Findings
Considering the applications in the turbine industry, it has been determined that the WEDM method is suitable to meet the standards for the machinability of Inconel 625 alloy. In contrast, the AWJM method does not meet the standards. Namely, while the kerf angle was formed because the hole entrance diameters of the holes obtained with AWJM were larger than the hole exit diameters, the equalization of the hole entry and exit dimensions, thanks to the perpendicularity and tension sensitivity of the wire electrode used in the holes drilled with WEDM ensured that the kerf angle was not formed.
Originality/value
It is known that the surface roughness of the parts used in the turbine industry is accepted at Ra = 0.8 µm. In this study, the average roughness value obtained from the successful drilling of Inconel 625 alloy with the WEDM method was 0.799 µm, and the kerf angle was obtained as zero. In the cuts made with the AWJM method, thermal effects such as debris, microcracks and melted materials were not observed; an average surface roughness of 2.293 µm and a kerf of 0.976° were obtained.
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Monika Duchna, Iwona Cieślik, Alexander Kloshek, Bogusława Adamczyk-Cieślak, Magdalena Zieniuk, Dorota Moszczyńska and Jarosław Mizera
The purpose of this paper is to obtain high-temperature-resistant material with high density and to conduct microstructural investigations of 3D-printed Ni-based alloy 713C…
Abstract
Purpose
The purpose of this paper is to obtain high-temperature-resistant material with high density and to conduct microstructural investigations of 3D-printed Ni-based alloy 713C specimens.
Design/methodology/approach
High-density specimens of Ni-based alloy 713C were obtained by the optimizing selective laser melting (SLM) process parameters and an X-ray diffraction (XRD) analysis confirmed the occurrence of γ and γ′ phases and the presence of carbides in the SLM-manufactured Ni-based alloy 713C. The analysis of electron backscatter diffraction (EBSD) studies suggested a preferred 〈100〉 direction orientation and low angle misorientation for the SLM specimens.
Findings
The high-density specimens of Ni-based alloy 713C were obtained by the optimized SLM process parameters. XRD analysis confirmed the presence of γ and γ′ phases and carbides in the SLM-manufactured Ni-based alloy 713C. Analysis of EBSD studies suggested a preferred 〈100〉 direction orientation and low angle misorientation for the SLM specimen.
Originality/value
In this study, 3D-printed Ni-based alloy 713C with a high density of 99% was obtained for the first time, to the best of the authors’ knowledge.
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