Cogging is a key part in the production process of superalloy, but inclusions affect the performance of superalloy. It is therefore particularly important to study the effects of cogging on the inclusions in superalloy. In our study, the superalloy GH4738 was made by double vacuum smelting. Cogging was performed by unidirectional drawing, upsetting and drawing, and upsetting/drawing with radial forging. The types and distributions of the inclusions after the three cogging processes were analyzed using scanning electron microscopy, energy dispersive spectroscopy, and software such as Image Pro Plus. The results showed that double vacuum smelting essentially determined the types of the inclusions in the GH4738 superalloy. Four types of inclusions were found in the experiments: TiC-TiN-Mo-S composite, TiC-TiN composite, Ce-Mo-S composite, and SiC inclusions. In the case of cogging by unidirectional drawing, the average size of the inclusions first decreased and then increased, from the center to the edge. In the case of upsetting and drawing, and upsetting/drawing with radial forging, the average size of inclusions decreased from the center to the edge.

The microstructure and solidification behavior of nickel based GTD222 superalloy at different cooling rates are studied. The solidification of the GTD222 superalloy proceeds as follows: L→L+γ, L→L+γ+MC, L→L+(γ/γ ′)-Eutectic and L→η phase. The temperature of liquidus of GTD222 superalloy is 1360 °C while the solidus is slightly lower at 1310 °C, which due to the alloying elements redistribution. It was found that the dendrite arm spacing of the alloy decreased with the increase of cooling rate (From 200 μm at 2.5 K/min to 100 μm at 20 K/min).

Effects of oxygen content on microstructure and creep property of FGH96 superalloy were investigated. When oxygen content increased from 135ppm to 341ppm, prior particle boundary (PPB) rose from degree 2 to degree 3, and the size of γ′ phase on PPB enlarged from 1.07μm to 1.27μm, and MC carbide size grew from 77.4nm to 104.0nm. Meanwhile, the steady creep rate accelerated form 4.34×10-3 h-1 to 1.87×10-2 h-1, and the creep rupture life shortened from 176h to 94h, and the creep rupture mode transferred from intergranular and transgranular mixed fracture to along PPB fracture. During creep, the micro-twins formation and gliding will be restrained by ∑3 boundaries. FGH96 superalloy with higher oxygen content contains less ∑3 boundaries and its micro-twins cross slipped instead of single direction slip in lower oxygen content superalloy. Consequently, specimen with higher oxygen content creeped faster and raptured earlier.

The material undergoes high temperature and high strain rate deformation process during cutting process, may induce the dynamic recrystallization behavior and result the evolution of dynamic mechanical properties of the material to be machined. In this paper, the modified Johnson-Cook(J-C) model for Nickel based powder metallurgy superalloy considering dynamic recrystallization behavior in high strain rate and temperature is proposed. The dynamic mechanical properties of the material under different strain rates and temperature conditions are obtained by quasi-static compression test and split Hopkinson pressure bar (SHPB) test. The coefficients of the modified J-C model are obtained by linear regression method. The modified model is verified by comparison with experimental and model prediction results. The results show that the modified J-C model proposed in this paper can accurately describe the mechanical properties of nickel-based powder metallurgy superalloys at high temperature and high strain rate. Which provides help for studying the cutting mechanism and finite element simulation of nickel-based powder metallurgy superalloy.

Nickel-based Superalloy Inconel 718 is widely used in the aerospace industry for its excellent high-temperature strength and thermal stability. However, milling Inconel 718 presents challenges due to significantly increased cutting force and vibration, which is a typical difficult-to-machine material. This paper focuses on the milling process of Inconel 718, establishing a milling force model to analyze the force trends under various processing parameters. Finite element analysis is employed to study the stress and temperature fields during milling. Dynamic equations for milling Inconel 718 are developed, and stability lobe diagrams are generated based on modal experiments. Milling experiments on Inconel 718 validate the milling force model and finite element analysis results. The fmincon optimization algorithm is utilized to identify the optimal machining parameters for Inconel 718. Through this research, valuable insights into enhancing the efficiency and quality of Inconel 718 machining are provided. This study contributes to a deeper understanding of Inconel 718 milling behavior, offering crucial guidance for more efficient machining processes.

Nickel superalloys occupy a reasonably broad niche in the industry. One of this group's most common and well-known alloys is Inconel 718. Parts from Inconel 718 are used in aerospace, energy, automotive, and some other vital industries, which creates a demand for research and improvement of the machining conditions of this alloy. This article is devoted to the systematization and generalization of the accumulated experience of machining of Inconel 718 at turning operation. The research methodology is based on the Pareto distribution. In the study, more than 50 articles devoted to turning Inconel 718 were analyzed. The tool materials, methods, and types of coating used in turning Inconel 718 were analyzed. Finite element method modeling of processing processes has been considered. The trends in the selection of cutting parameters and the geometry of the cutting tool and finite element method modeling of processing processes have been considered. Lacuna for promising future research was formulated.

This work aims at improving surface integrity and LCF life of machined Inconel 718. The correlation between the LCF life of Inconel 718 and various states of machined surface integrity is explored. In this paper, the surface integrity of Inconel 718 specimens is enhanced by low plasticity burnishing (LPB). The LCF life with different surface integrity specimens is predicted by micro-macro finite element method (FEM). Firstly, the LCF specimens with different surface integrity are machined by turning (turned specimen), polishing (matrix specimen) and LPB process (LPBed specimen). Secondly, the LCF experiment is carried out to reveal the effect of surface integrity on LCF life. Finally, the LCF micro-macro FEM model is proposed to predict the LCF of machined Inconel 718 specimens. The representative volume element (RVE) model is established based on the measured surface integrity and microstructure of Inconel 718 specimens. The effect of surface integrity on LCF life is transformed to equivalent load. The micro-macro FEM model combined with Tanaka-Mura dislocation crack initiation theory and extended finite element method (XFEM) is applied to predict the LCF life the machined specimens. The study results show that the LCF life of LPBed specimens can be improved by 90.5% and 36.1% compared with that of turned specimens and polished matrix specimens, respectively. The errors between FEM prediction results and experimental results are 13.1%, 9.2% and 12.2%, respectively. The proposed micro-macro FEM model could be utilized to predict the LCF life of Inconel 718 with different surface integrity, and further to apply the LCF life prediction in industry.

K417G Ni-based superalloy is widely used in aeroengine turbine blade for its excellent properties. However, the aeroengine rotor blade zigzag crown appears early failure frequently, which is because of the wear problems occurring in the working process. Laser forming repairing (LFR) is a promising technique to repair these damaged blades. Unfortunately, the laser formed Ni-based superalloys with high content of (Al + Ti) have a high cracking sensitivity. In this paper, the crack characterization of the LFRed K417G, the microstructure, microhardness and tribological properties of the coating before and after laser remelting are presented. The results show that the microstructure of as-deposited K417G consists of γ phase, γ′ precipitated phase, γ + γ′ eutectic and carbide. Cracking mechanisms including solidification cracking, liquation cracking and ductility dip cracking are proposed based on the composition of K417G and processing characteristics to explain the cracking behavior of the K417G superalloy during LFR. After laser remelting, the microstructure of the coating has been refined, and the microhardness and tribological properties has been improved. Laser remelting can decrease the size of the cracks in the LFRed K417G but not the number. Therefore, laser remelting can be applied as an effective method for strengthening coating and as an auxiliary method for controlling cracking.

In this work, a systematic study was conducted on the fabrication of multi-material components obtained employing Laser-Powder Bed Fusion (L-PBF) technology. The idea of making multi-material components is a winning capability of additive technologies because it allows the fabrication of Functionally Graded Materials (FGMs) with the customization of parts according to different required properties. The transition from one material to another was achieved gradually and continuously within the same layer using ad-hoc equipment designed for L-PBF systems with a powder spreading technique based on coaters or rollers. The influence of the relative position of the different materials within the powder chamber and the geometry of the developed equipment on the metallurgical and mechanical properties of the manufactured samples was evaluated. The performed tests involved the use of two materials, a nickel-based superalloy, and a stainless steel, having different chemical, physical and mechanical properties to obtain gradual properties variation in the manufactured samples. Based on the results of post-process characterization obtained through metallographic, chemical, and mechanical analysis, the relative positions of the materials and the geometry of the developed equipment have a limited effect on the sample’s manufactured properties. The characteristics of the FGM zone depend on the nature of the employed powders, and its extent coincides with that defined during the design of the divider.