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The enhanced performance of aerospace equipment drives parts development towards integration, complexity, and structural optimization. This advancement promotes metal near-net fabrication technologies like wire electrical discharge machining (WEDM) and 3D printing. However, the high initial surface roughness from WEDM or 3D printing poses significant challenges for the high-performance surface finishing required. To effectively reduce the surface roughness of the workpieces with high initial surface roughness, this paper proposes pulsed unipolar-polarisation plasma electrolytic polishing (PUP-PEP). The study examined the material removal mechanisms and surface polishing quality of PUP-PEP. This technique combines the high current density and material removal rate of the electrolytic polishing mode with the superior surface polishing quality of PEP through voltage waveform modulation. For an Inconel-718 superalloy part fabricated by WEDM, PUP-PEP reduced surface roughness from Ra 7.39 μm to Ra 0.27 μm in 6 min under optimal conditions. The roughness decreased from Ra 7.39 μm to Ra 0.78 μm in the first 3 min under pulsed unipolar-polarisation voltage, resulting in a remarkable 233% increase in efficiency compared to that with conventional PEP. Subsequently, the voltage output voltage is transformed into a constant voltage mode, and PEP is continued based on PUP-PEP to finally reduce the workpiece surface roughness value to Ra 0.27 μm. The proposed PUP-PEP technology marks the implementation of 'polishing' instead of conventional rough-finish machining processes, presenting a new approach to the surface post-processing of metal near-net fabrication technologies. [ABSTRACT FROM AUTHOR]

This study investigates the microstructural evolution and its effect on the fatigue performance of a novel nickel-based powder superalloy FGH4113A (WZ-A3) after long-term aging at 760 °C and 815 °C. The results show that long-term aging both at 760 °C and 815 °C has no significant effect on the grain size and morphology of the alloy. After aging at 760 °C for up to 2020 h, the size of the γ′ phase remains unchanged, and its morphology transitions from nearly square to nearly spherical. During long-term aging at 815 °C for 440 h, γ′ phase coarsening and spheroidizing occur simultaneously. With prolonged aging time, the size and spheroidization degree of the γ′ phase further increase. During long-term aging up to 440 h at 760 °C, the dispersed granular MC and M6C carbides dissolve and re-precipitate. By 2020 h of aging, flocculent carbides precipitate and non-continuous M6C and M23C6 accumulate at grain boundaries. After long-term aging at 815 °C for 440 h, flocculent carbides begin to precipitate within the grains. By 2020 h of aging, a large amount of flocculent carbides precipitate with significant coarsening and enrichment of the grain boundary carbides. Due to the insignificant coarsening of the γ′ phase as well as the enrichment and precipitation of the grain boundary carbides, the fatigue performance of the alloy decreases slightly after long-term aging. [ABSTRACT FROM AUTHOR]

Copyright of Rare Metals is the property of Springer Nature and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

The present study is focused on the investigation and simultaneous optimisation of MQL-turning parameters with the application of the weighted Mayfly algorithm for sustainable machining of Nimonic 75. The nanofluid used for the experimental work is graphene oxide dispersed rice bran oil. The parameters of cutting velocity, feed rate, nozzle angle, and nozzle distance were considered for processing characteristics of force, roughness, and residual stress. The weight in the Mayfly algorithm is determined using a grey relational coefficient (GRC). The weight importance calculated for each response is compared with the different schemes in the algorithm. The result showed that the parameters with these schemes had different optimal values. At optimal factor levels determined using GRC in the Mayfly, the algorithm improved 'F-value = 0.40' compared to factor levels in other methods. Compared to experimental results, the optimised value reduces the surface roughness, cutting force, and residual stress by 30%, 3%, and 10%, respectively. The feed rate, cutting velocity, and nozzle distance are the most vital parameters for optimising the output response with the GRC-Mayfly process. [ABSTRACT FROM AUTHOR]

Since the solidification structure of metals cast by conventional mold casting often has porosity defect, the combination of low voltage pulsed magnetic field and thermally controlled solidification was used to solve this defect. The combination method is called magnetic‐thermal coordinated control solidification. Pulsed magnetic field stirring can refine equiaxed grains, and the thermally controlled solidification method can eliminate the concentrated shrinkage cavity and reduce the dispersed shrinkage porosity. Thus, a superalloy K4169 with fine equiaxed grains, low content of dispersed shrinkage porosity and without concentrated shrinkage cavity defect is fabricated by magnetic‐thermal coordinated control solidification. [ABSTRACT FROM AUTHOR]

The Inconel 718 superalloy demonstrates the potential to fabricate high-temperature components using additive manufacturing. However, additively manufactured Inconel 718 typically exhibits low strength, necessitating post-heat treatments for precipitate strengthening. This study investigated the microstructures and mechanical properties of the Inconel 718 superalloy fabricated via laser powder bed fusion. The room-temperature and high-temperature tensile properties of the Inconel 718 alloy samples following various post-heat treatments were evaluated. The results indicate that the as-built samples exhibited columnar grains with fine cell structures. Solution treatment resulted in δ phase formation and grain recrystallization. Subsequent double aging led to finely distributed nanoscale γ′ and γ″ particles. These nanoscale particles provided high strength at both room and high temperatures, resulting in a balanced strength and ductility comparable to the wrought counterpart. High-temperature nanoindentation analyses revealed that the double-aging samples exhibited very high hardness and low creep rates at 650 °C. [ABSTRACT FROM AUTHOR]

This work elucidates the interactions between Re and hydrogen at γ/γ′ interfaces, enhancing the hydrogen-embrittlement resistance of nickel-based single-crystal superalloy (Ni-SX). The H-charged Ni-SX exhibits severe embrittlement characterized by the appearance of parallel dislocation slip bands and micro-cracks, which could be effectively mitigated through improving the Re content. The segregation behaviors of hydrogen at γ/γ′ interfaces, as captured by hydrogen microprint technique, significantly diminish interfacial cohesion strength by reducing the local atomic bonding strength. Detailed characterizations of bonding charge density highlight that Re plays a crucial role in reducing hydrogen embrittlement susceptibility by suppressing the hydrogen-induced degradation of bonding strength. The role of Re on hydrogen-embrittlement resistance of superalloys is investigated through tensile tests and first-principles calculations, revealing the suppressive effect of Re on hydrogen-induced decohesion behaviors at γ/γ′ interface. [ABSTRACT FROM AUTHOR]

The microstructure and 650 °C tensile properties of a compositionally graded IN718-René41 (718-R41) superalloy fabricated by laser blown-powder directed energy deposition (DED-LB/M) are investigated to understand structure–property relationships and baseline tensile properties. Digital Image Correlation (DIC), in situ neutron diffraction, and conventional characterization techniques are performed to study the as-built and heat-treated states. The applied heat treatment generates static recrystallization and equiaxed grains in 718-rich compositions, while R41-rich compositions remain partially or un-recrystallized possibly influenced by a higher MC carbide fraction (>0.5%). The yield strengths of the 718 and R41 sections in the heat-treated state are comparable to wrought forms but the graded compositions show weakness due to unoptimized heat treatment. Diffraction elastic constants first decrease and then increase along the 718-R41 composition gradient, while a small difference is observed between the as-built and heat-treated states and γ, γ′ phases. Overall, the compositionally graded region shows a smooth transition in the elastic properties. Grain-level load transfer from the (220) to (200) grains shows compositional dependence, and qualitatively agrees with DIC-measured macroscopic yield strength. Within the (200) grains, the γ/γ′ phases deform elastically until the γ phase yields and afterwards, the γ′ phase takes load from the γ phase. [ABSTRACT FROM AUTHOR]

The water-assisted laser trepanning method has been proven to improve the quality of laser drilling; however, the effect of water temperature on this process is currently unclear. In order to investigate the influence of water temperature on the quality of holes produced via water-assisted laser trepanning in superalloys, this study used the controlled variable method to investigate the effects of three water temperatures—low temperature (2 °C), normal temperature (20 °C), and high temperature (70 °C)—on the following factors: spatter, hole diameter, taper angle, hole sidewall morphology, and recast layer. The results show that the spatter around the hole reduced, the hole entrance/exit diameter increased, and the roughness of the hole's sidewall decreased with an increase in single-pulse energy. However, the effect of single-pulse energy on the recast layer was not obvious. As the temperature of the water increased, the hole entrance/exit diameter increased, and the roughness of the hole's sidewall decreased. When the single-pulse energy was 1.0–1.9 J, using a lower water temperature produced a hole with a smaller taper angle. Compared with a water temperature of 20 °C, the movement of the melt film on the hole's sidewall accelerated when the water temperature was 70 °C; as a result, more molten material could be removed from the hole, resulting in a decrease in the thickness of the recast layer. However, when the water temperature was 2 °C, the heat-affected zone and the thickness of the recast layer decreased more significantly. The results of this study provide technical support for the optimization of water-assisted laser drilling. [ABSTRACT FROM AUTHOR]

Copyright of Rare Metals is the property of Springer Nature and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

Abstract The enhanced performance of aerospace equipment drives parts development towards integration, complexity, and structural optimization. This advancement promotes metal near-net fabrication technologies like wire electrical discharge machining (WEDM) and 3D printing. However, the high initial surface roughness from WEDM or 3D printing poses significant challenges for the high-performance surface finishing required. To effectively reduce the surface roughness of the workpieces with high initial surface roughness, this paper proposes pulsed unipolar-polarisation plasma electrolytic polishing (PUP-PEP). The study examined the material removal mechanisms and surface polishing quality of PUP-PEP. This technique combines the high current density and material removal rate of the electrolytic polishing mode with the superior surface polishing quality of PEP through voltage waveform modulation. For an Inconel-718 superalloy part fabricated by WEDM, PUP-PEP reduced surface roughness from R a 7.39 μm to R a 0.27 μm in 6 min under optimal conditions. The roughness decreased from R a 7.39 μm to R a 0.78 μm in the first 3 min under pulsed unipolar-polarisation voltage, resulting in a remarkable 233% increase in efficiency compared to that with conventional PEP. Subsequently, the voltage output voltage is transformed into a constant voltage mode, and PEP is continued based on PUP-PEP to finally reduce the workpiece surface roughness value to R a 0.27 μm. The proposed PUP-PEP technology marks the implementation of ‘polishing’ instead of conventional rough-finish machining processes, presenting a new approach to the surface post-processing of metal near-net fabrication technologies.

This work investigates the effect of cyclic creep on the long-term oxidation of a directionally-solidified nickel-based superalloy DZ445 up to 1800 h. The stress application of cyclic creep refines the oxides, increases the oxidation weight gain, reduces the oxidation rate exponent, and decreases the activation energy. It enhances the content of Al2O3 and TiO2 in the outermost layer and in the sub-outer layer of CrTaO4 in the film. It delays the formation of the continuous innermost layer of Al2O3 and the sub-inner layer that is rich in Al2O3. The change of phase content and type in the oxidation layers could be ascribed to the diffusion kinetic effect of cyclic creep stress in the superalloy.

A deformed superalloy with γ′ content reaching 73% has been designed by ourselves. In this work, the problems of preparation and deformation caused by the high γ′ phase content were solved by the electron beam smelting layered solidification technique (EBS-LST) and hot extrusion. Initially, the superalloy with low segregation and fine microstructure was prepared by EBS-LST, followed by conducting hot deformation experiments at different temperatures and strain rates. The compression curves are corrected, and the constitutive model, recrystallization models and thermo-mechanical processing maps were established based on the corrected curves, and the recrystallization mechanisms were analyzed by TEM and EBSD. Finally, the suitable hot extrusion parameters were obtained indirectly through the hot processing map, and the designed alloy was hot extruded. The microstructure of the extruded alloy is free of cracks and is characterized by fine equiaxed grains.

The interfacial behaviors between protective coatings and substrate single-crystal superalloys significantly impact their service performances. This work focuses on the elements interdiffusion and microstructural evolution at the interface between a NiCrAlY coating and a series of high-Mo Ni3Al-based single-crystal superalloys, through the coupled phase-field simulations and DICTRA kinetics calculations of their model systems. The critical roles of Al and Cr played in the microstructural evolution at coating/superalloy interface have been confirmed, which requires the appropriate content decreases of Al and Cr in the coating at 1100 °C. However, the addition of Mo reduces the driving force of element diffusion from coating to substrate by increasing the activities of Al and Cr in superalloy. Moreover, increasing the Mo content in superalloy from 8 wt% to 10 wt% could also counteract the promoting effect of Al on Ni mobility and mitigate the γ′ coarsening and detrimental TCP precipitation. Therefore, the effects of Mo enable the reasonable increase of Al content in coating to better balance the interfacial stability and oxidation resistance of coated superalloy, besides its advantage in reducing the anisotropy of TCP precipitate. The obtained interfacial evolution mechanisms resulting from the phase transformation thermodynamics and element interdiffusion kinetics are expected to aid the coating design for advanced single-crystal superalloys servicing at ultra-high temperature.

Purpose – As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed. Design/methodology/approach – Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained. Findings – In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials. Originality/value – With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

The spot-welding defects of highly alloyed Ni-base superalloy GH4065A were investigated by using SEM and EBSD analysis methods. Effects of the welding defects on fatigue life and fracture behavior were studied by comparing thin plate samples with a central hole that were non-welded，densely welded and sparsely welded respectively. The results show that the lack-of-fusion defect，solidification crack and liquation crack are the main welding defects responsible for significant reductions in low-cycle fatigue life as well as combined low and high cycle fatigue life. These welding defects result in a transition of the fatigue crack initiation site from the inner surface of the central hole in the non-welded sample to the welding spot in the welded sample，leading to 44%-83% reductions in low-cycle fatigue life at 700 ℃/700 MPa. For the combined low and high cycle fatigue conditions（with a stress amplitude of 700 MPa for the low cycle loading part and 100 MPa for the high cycle loading part），the welding defects not only alter the site at which fatigue cracks initiate，but also make the crack propagation mode more intergranular. This results in dramatic decreases of over 85% in the fatigue life of welded samples at both 600 ℃ and 700 ℃. Due to shorter distance between the welding spot and the central hole，densely-welded samples exhibit a slightly lower level of fatigue life under low-cycle loading conditions compared to sparsely welded samples. However，the fatigue life difference between them becomes negligible when subjected to combined low and high cycle loadings.

This work elucidates the interactions between Re and hydrogen at γ/γ′ interfaces, enhancing the hydrogen-embrittlement resistance of nickel-based single-crystal superalloy (Ni-SX). The H-charged Ni-SX exhibits severe embrittlement characterized by the appearance of parallel dislocation slip bands and micro-cracks, which could be effectively mitigated through improving the Re content. The segregation behaviors of hydrogen at γ/γ′ interfaces, as captured by hydrogen microprint technique, significantly diminish interfacial cohesion strength by reducing the local atomic bonding strength. Detailed characterizations of bonding charge density highlight that Re plays a crucial role in reducing hydrogen embrittlement susceptibility by suppressing the hydrogen-induced degradation of bonding strength.

The sensitivity of grain boundary (GB) cracks often limits the high-temperature plasticity of superalloys. The 750 ℃ tensile deformation of fine-grained Ni-Co based wrought superalloys was observed in situ using a scanning electron microscope (SEM) equipped with an electron backscatter diffraction (EBSD) probe to clarify the texture formation and GB response. The GB stress concentration depends on the grain orientation and slip system alignment on both sides. This reflects the ability of GBs to cope with deformation incompatibility. This study provides valuable insights for predicting the failure of polycrystalline superalloys and offers new ideas for microstructure evaluation and GB design.

The sensitivity of grain boundary (GB) cracks often limits the high-temperature plasticity of superalloys. The 750 ℃ tensile deformation of fine-grained Ni-Co based wrought superalloys was observed in situ using a scanning electron microscope (SEM) equipped with an electron backscatter diffraction (EBSD) probe to clarify the texture formation and GB response. The GB stress concentration depends on the grain orientation and slip system alignment on both sides. This reflects the ability of GBs to cope with deformation incompatibility. This study provides valuable insights for predicting the failure of polycrystalline superalloys and offers new ideas for microstructure evaluation and GB design. IMPACT STATEMENT: The lattice rotation and GB response of Ni-Co based fine-grained wrought superalloys under 750 ℃ deformation were explained through in-situ observation, which helps predict the superalloys' service behavior. [ABSTRACT FROM AUTHOR]

The microstructure evolution under over-temperature （1070-1250 ℃） and tensile/compressive stress （30-90 MPa） conditions of IC10 alloy was analyzed to simulate the alloy deterioration process during over-temperature operation of gas turbine blades.The results show that the degeneration of secondary γ' phase in IC10 alloy during thermal exposure without stress includes spheroidizing， coarsening， and redissolution. As thermal exposure temperature and time increase， the shape of secondary γ' phase transforms from flower-like to rounded cubic and spherical， driven by the decrease of γ/γ' phase interface energy. The area fraction of secondary γ' phase decreases with the increase in temperature and the prolonging of time. The secondary γ' phase is completely redissolved after thermal exposure at 1225-1250 ℃ for more than 50 h. The size of secondary γ' phase increases with the increase in temperature and time. The coarsening of γ' phase conforms to the Lifshitz-Slozov-Wagner theory controlled by diffusion. Under the overtemperature and stress condition， the rafting of γ' phase gradually intensifies with the increase of temperature. The tensile stress promotes the N-type rafting of γ' phase perpendicular to the stress axis， while the compressive stress promotes the P-type rafting of γ' phase parallel to the stress axis. The γ' phase rafting process is faster under the tensile stress state than under the compressive stress. The microstructure of IC10 alloy under over-temperature and stress conditions can be used to evaluate the service conditions of the blade after service.

A method of quadrupole inductively coupled plasma mass spectrometry (Q-ICP-MS) based on oxygen reaction mode was established for the accurate determination of trace impurity elements in superalloys. The effect of the collision/reaction mode on the removal of mass spectral interference was investigated. By contrast, the polyatomic mass spectral interference on the target element Cd can be effectively removed under oxygen dynamic reaction cell (DRC-O2) mode. The signal-to-noise ratio (SNR) peaked when the gas flow was 2 mL/min, and the detection limit was approximately three orders of magnitude lower than that under standard (STD) mode. In addition, the elimination mechanism of mass spectrometric interference was studied. It was found that for the element X (X=Rb, Nb, Mo, Cs, Ta, W or U), the conversion of the interferent species XO to the non-interferent species XOO is a spontaneous reaction when the bond energy of X−O bond is higher than that of O−O bond. Therefore, it is easier to generate ions of XOO species when there is adequate O2 present in the ion source, so as to eliminate XO interference. Based on these results, experiments were carried out to determine elements of Rb, Nb, Mo, Cs, Ta, W and U. The matrix simulated solutions containing high concentration of Mo, Nb, Ta, and W were used to evaluate the methodological parameters for the measurement of trace Cd, Ag, Au, and Hg impurities, respectively. The limit of detection (LOD) of the trance elements is 0.08-0.31 μg/g, the relative standard deviation (RSD) of the measurement is 2.3%-3.1% (n=6), and the spiked recovery is in the range of 98%-103%. The reliability of the method was further verified by certified superalloy reference materials. Finally, the trace impurities in three types of superalloy samples were measured. The results indicated that the proposed method can achieve rapid, reliable analysis with low detection limit. Besides, it can meet the measurement requirement of trace impurities when the main elements of Mo, Nb, Ta and W exist in superalloy.

The goal of this study is to investigate the impact of beam deflection pattern characteristics on microstructure and porosity formation during Powder Bed Fusion Electron Beam Melting (PBF-EB/M) processing of Inconel 718. Specifically, the complex interplay between “beam return time” and “beam jump distance” and their influence on heat accumulation, porosity, and grain formation is explored. The findings reveal that beam jump distance plays a critical role in the transition from columnar to equiaxed solidification, while beam return time is essential for achieving optimal heat accumulation and minimizing porosity. By controlling these two universal beam deflection pattern characteristics, a novel multi-spot scanning strategy was developed, enabling the formation of a fine-grained equiaxed microstructure. It is demonstrated that sufficient heat accumulation is essential for a pore-free bulk material and can be achieved by short beam return times or small beam jump distances. However, for equiaxed grain formation, a large beam jump distance, i.e., a wide distribution of melt pools, is required. Therefore, heat accumulation must be controlled by means of the beam return time if equiaxed grains are aimed for. Additionally, it is found that higher beam currents are beneficial for equiaxed grain formation, but the strongest impact on the columnar to equiaxed transition is attributed to the beam movement pattern itself. This approach offers insights into microstructure control and process reliability, regardless of the specific PBF technique employed, and enables application-specific microstructure design of Inconel 718.

Owing to their unique high-temperature mechanical properties and outstanding high-temperature oxidation resistance, superalloys have become key materials in aviation, aerospace, petrochemical, metallurgy, electric power, automotive, and other industrial fields. Due to the structural complexity and high manufacturing cost of the hot sections of aeroengines, vessel engines, and gas turbines, the development and practicality of superalloy welding technology are critical to satisfying the design and maintenance requirements of hot sections. In this work, the research progress of superalloy fusion welding is described. Its advantages and application scope, such as arc welding, electron beam welding, and laser welding, are elaborated. Common types of welding cracks are introduced, and the mechanisms and influencing factors of solidification cracks, liquation cracks, strain-age cracks, and ductility-dip cracks are summarized. The primary techniques to enhance the weldability of fusion welding are also examined in terms of heat input, material composition, microstructure, and welding residual stress. The requirements for the temperature-bearing level of superalloys in industrial development are constantly increasing; thus, the types of superalloys are also being iteratively updated. They have evolved from deformed superalloys to ordinary cast polycrystalline superalloys to novel superalloy materials such as directional solidification and single-crystal superalloys. Thus, continuously conducting welding research on emerging superalloys, traditional nonweldable superalloys, and dissimilar materials that are extremely incompatible with metallurgy is necessary. Because the composition and microstructure of the base material have an important bearing on weldability, it is necessary to strengthen the composition design of emerging superalloys and conventional nonweldable superalloys in future works. Moreover, it is critical to pay attention to the improvement of welding process technology and pre- and post-weld treatment methods. In particular, research on detection and elimination measures of welding residual stress should be strengthened, which is one of the most effective approaches for lowering the weld crack-sensitivity of superalloys. This is of great importance for synergistically enhancing the welding performance of superalloys. Moreover, monitoring and simulation techniques for the welding process can be used to perform in-depth research on scientific issues such as molten pool flow and welding heat and mass transfer during the fusion welding process. This is of great scientific value for promoting the development of fusion welding technology. Based on the foundation of enhancing welding processes, future work on automation and intelligence of welding processes should also gradually deepen, which is one of the important directions to improve welding stability and reliability and promote the widespread application of superalloy fusion welding.

Superalloys play a critical role in aerospace applications due to their exceptional mechanical properties at high temperatures. The application of magnetic fields to regulate superalloys presents novel avenues for optimizing microstructures, controlling solidification defects, and enhancing their high-temperature properties. This paper provides a comprehensive review of research findings on the influence of magnetic fields on the microstructure and properties of superalloys. It systematically elucidates the effects of different types and intensities of magnetic fields on alloy solidification. Moreover, this paper extensively explores the effects of various types of magnetic fields on the phase composition, microstructure, and properties of superalloys, including Ni-based and Co-based alloys, as well as high-entropy alloys. The underlying mechanisms behind the impact of magnetic fields on these alloy types are thoroughly analyzed. Finally, the last section offers a brief summary of the current development status and prospects of magnetic field-regulated superalloys.

This paper investigates the distribution pattern of welding porosity defects in annular weld seams of superalloy during laser welding. The results reveal that the initial portion of the annular weld seam exhibits a higher density and larger size of porosity defects compared to the ending portion. At a laser power of P = 360 W, the numerical simulation combination showed that the A1 region's average cooling rate is 8.767 × 103 °C/s and the A2 region is 8.151 × 103 °C/s that the thermal conduction effect at the initial welding position leads to an elevation in the base metal temperature in the subsequent unwelded region, thereby reducing the solidification rate of the molten pool in the latter half of the weld seam and effectively decreasing the porosity rate at the weld seam. Furthermore, the study demonstrates that elevating the base metal temperature can effectively modify the cooling rate of the molten pool, thereby influencing the formation of porosity defects. At a laser power of P = 360 W, increasing the base metal temperature to 600 °C reduces the cooling rate of the molten pool from 8.767 × 103 °C/s at a base metal temperature of T = 20 °C to 7.451 × 103 °C/s, leading to a decrease in the porosity rate from 3.357% to 0.022%. At a laser power of P = 672 W, increasing the base metal temperature to 600 °C reduces the cooling rate of the molten pool from 6.781 × 103 °C/s at a base metal temperature of T = 20 °C to 5.056 × 103 °C/s, leading to a decrease in the porosity rate from 8.214% to 0.002%. The increase in laser power brings more heat input, so the solidification rate of the molten pool decreases, but the porosity increases significantly. However, increasing the base temperature can effectively suppress the porosity defects under different laser powers. The research further reveals the relationship between welding porosity rate and cooling conditions, providing a control strategy for achieving low porosity rate welds.

Nickel-based single-crystal superalloys are designed for extreme conditions due to their superior corrosion and creep resistance properties. However, these pose challenges in the subsequent recycling after reaching their end-of-life. Molten magnesium (Mg) can rapidly corrode the stable spent nickel-based superalloys and selectively dissolve nickel (Ni). This waste-free process represents an effective method for recycling spent superalloys and accomplishing metal regeneration. This study investigates the mechanism of selectively dissolving Ni from DD5, a nickel-based single-crystal superalloy, by optimizing process temperature, time, and Mg content in an inert atmosphere. Vacuum distillation was employed to separate the resulting Mg, residual superalloy (i.e., the material left post-extraction), and Ni-rich alloy (i.e., the metal product selectively extracted). The findings revealed that the residual superalloy after selective Ni dissolution is characterized by a porous skeleton structure with pore sizes predominantly ranging from 2 to 30 nm and a low compressive strength which is 1/10 of the original DD5 superalloy.

Carbon nanofibers (CNFs) and graphene nanosheets (GNs) are introduced to obtain nano-sized TiC particles in a novel additive manufactured Ni-Co-based superalloy. The double strengthening effects of reaction-induced TiC and remaining CNFs/GNs are conceptualized in the present paper. The CNFs and GNs act as heterogeneous nucleation sites for the formation of uniformly distributed TiC nanoparticles, which inhibits the crack and homogenize the microstructure. Interestingly, the existence of remaining GNs/CNFs is revealed via 3D atom-by-atom tomographic reconstruction technology for the first time. This unique combination of nanoparticles and residual CNFs/GNs nanofillers has great potential to develop superalloys with excellent properties.

As major forming elements of γ′ strengthening phase, Al and Ti are critical for achieving superior properties of Ni-based superalloy. However, Al + Ti over 6 wt% leads to poor printability and cracking during additive manufacturing. In this work, the printability and properties of a nickel-based superalloy with Al + Ti reaching 7 wt% is synchronously improved via alloying minor Sc, the mechanism behind that is revealed by investigating the effects of Sc on the grain size, precipitation, and tensile fracture behavior of that nickel-based superalloy. This work provides a promising alternative method for optimizing the performance of superalloys prepared by additive manufacturing.

The paper investigates various methods of microfinishing and arrives at the best technique to produce a very smooth surface. Various setups, with and without oscillation, were developed, together with a microfinishing attachment used on conventional lathes and milling machines. The workpiece material used was an amorphous nickel–phosphorus Ni–P alloy. The surface roughness parameters, such as Sa, Sv, and Sp, were measured with the TalySurf CCI6000 instrument. For the measurement of the surface protrusions, an "analysis of islands" technique was used at various levels of cut-off. The 2BA method—machining below the workpiece axis with oscillation—turned out to be the most effective method applied because it had the highest density of protrusions while having the smallest value of surface roughness. Non-oscillation with the machining zone below the axis also becomes effective, indicating that repositioning can compensate for a lack of oscillation. Already, the very compact surface structure achieved with minimized depths in the valleys by the 2BA method supported the improvement in tribological performance and increase in load-carrying capacity, together with lubricant retention enhancement. These results show that the microfinishing process can be optimized by parameter tuning, and also, non-oscillating methods could come to be a practical alternative, probably reducing the complexity of equipment and cutting costs. Further studies need to be aimed at the scalability of these methods and their application to other materials and fields. [ABSTRACT FROM AUTHOR]

A method of quadrupole inductively coupled plasma mass spectrometry (Q-ICP-MS) based on oxygen reaction mode was established for the accurate determination of trace impurity elements in superalloys. The effect of the collision/reaction mode on the removal of mass spectral interference was investigated. By contrast, the polyatomic mass spectral interference on the target element Cd can be effectively removed under oxygen dynamic reaction cell (DRC-O2) mode. The signal-to-noise ratio (SNR) peaked when the gas flow was 2 mL/min, and the detection limit was approximately three orders of magnitude lower than that under standard (STD) mode. In addition, the elimination mechanism of mass spectrometric interference was studied. It was found that for the element X (X=Rb, Nb, Mo, Cs, Ta, W or U), the conversion of the interferent species XO to the non-interferent species XOO is a spontaneous reaction when the bond energy of X−O bond is higher than that of O−O bond. Therefore, it is easier to generate ions of XOO species when there is adequate O2 present in the ion source, so as to eliminate XO interference. Based on these results, experiments were carried out to determine elements of Rb, Nb, Mo, Cs, Ta, W and U. The matrix simulated solutions containing high concentration of Mo, Nb, Ta, and W were used to evaluate the methodological parameters for the measurement of trace Cd, Ag, Au, and Hg impurities, respectively. The limit of detection (LOD) of the trance elements is 0.08-0.31 μg/g, the relative standard deviation (RSD) of the measurement is 2.3%-3.1% (n=6), and the spiked recovery is in the range of 98%-103%. The reliability of the method was further verified by certified superalloy reference materials. Finally, the trace impurities in three types of superalloy samples were measured. The results indicated that the proposed method can achieve rapid, reliable analysis with low detection limit. Besides, it can meet the measurement requirement of trace impurities when the main elements of Mo, Nb, Ta and W exist in superalloy. [ABSTRACT FROM AUTHOR]

Powder metallurgy (PM) processed nickel-based superalloys are increasingly employed in the hot section of gas turbine engines for parts such as high-pressure (HP) compressors and turbine rotor discs over more traditional cast and wrought options such as Inconel 718 due to its improved high-temperature properties. In this paper, the surface integrity and geometrical/dimensional accuracy of holes initially rough drilled using worn tools and subsequently finish plunge end milled in a proprietary PM-processed Ni-based superalloy, were assessed and compared. The influence of tool wear on hole quality after finish plunge end milling was also investigated. Significant improvement in hole quality was evident following finishing with reductions in surface roughness (up to ~86%), subsurface microhardness (up to ~125 HK 0.05) and workpiece microstructure deformation/damage (up to ~80% in terms of average depth) compared to corresponding rough drilled holes. Evidence of chatter marks on holes machined with worn plunge end mills was observed, despite exhibiting reduced surface roughness levels (~45-73%). Generally, somewhat improved hole surface integrity (reduced subsurface deformation by ~47-64%) and geometrical accuracy (circularity decreased by ~10-25%) were produced when employing new tools. [ABSTRACT FROM AUTHOR]

Challenges in drilling nickel-based superalloys, such as Inconel 718 (IN718), are multifaceted. High requirement of hole surface quality in drilling such alloy must deal with extreme material properties and complex process condition in drilling operation. This paper presents an experimental investigation on the effect of PVD coated solid carbide drills under different internal cooling schemes on hole quality in drilling IN 718 alloy. Three types of solid carbide drills were used in the series of drilling experiments, including PVD coated and uncoated drills, and different design in the number of internal cooling channels, two channels and four channels. The objective of the investigation is to assess the effect of coating and efficiency of internal cooling on surface quality in drilling IN718 alloy. Surface quality on drilled holes in terms of roughness, burr formation, subsurface deformation and strain hardening has also been measured and analyzed on the machined specimen. The roughness and burr size on drilled holes demonstrated little differences among the three types of testing drills. Surface roughness was severely deteriorated by the chip trapped in the hole leaving scratch and smears on the surface. Nevertheless, the scheme of internal cooling channels and PVD coating exhibited noticeable influence on quality of drilled hole surface. [ABSTRACT FROM AUTHOR]

Copyright of Journal of Materials Engineering / Cailiao Gongcheng is the property of Journal of Materials Engineering Editorial Office and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

In order to evaluate the abrasive belt grinding performance, this paper proposes to conduct nickel-based superalloy robot abrasive belt grinding experiment based on different types of abrasive belts with multiple grit sizes. First, the single grinding performance evaluation is performed through five performance parameters: material removal rate, surface roughness, tangential force, specific grinding energy, and specific wear height. Then, based on the evaluation results of single grinding performance, a weighted evaluation function is established to comprehensively evaluate the grinding performance. It is found that the structured abrasive belt has relatively better grinding performance. The main factors affecting the abrasive belt grinding performance are identified through the evaluation results, with the effect of grit size being more significant. In addition, this paper analyzes the characteristics of material deformation based on the grinding subsurface microstructure, and discusses the effects of abrasive belts on material deformation. [ABSTRACT FROM AUTHOR]

Copyright of Journal of Aeronautical Materials is the property of Editorial Board of Journal of Aeronautical Materials and its content may not be copied or emailed to multiple sites or posted to a listserv without the copyright holder's express written permission. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)

A combined stamping–bulging forming process was proposed to achieve high-precision forming of large-diameter, ultra-thin-walled, superalloy welded S-type corrugated diaphragms. The underlying principle is to enhance the diaphragm's forming accuracy by increasing the plastic deformation region and reducing springback. Using the ABAQUS version 6.14 finite element analysis software, finite element models were constructed for the stamping, hydraulic bulging, and combined stamping–bulging forming processes of the welded S-type metal corrugated diaphragms. A comparative analysis was conducted on the forming processes of the welded S-type metal corrugated diaphragms under the three forming methods, focusing on equivalent stress, distribution of wall thickness, and forming accuracy. This analysis determined the optimal forming process and the corresponding process parameters for superalloy welded S-type metal corrugated diaphragms. The results show that under a constant drawing force, as the bulging pressure increases, the plastic deformation of the straight sections of the diaphragm becomes more pronounced, resulting in improved shape accuracy. The combined stamping–bulging forming process guarantees the highest degree of shape accuracy for the diaphragm. The optimal process parameters were identified as a 30 t force and a 5 MPa pressure, with a maximum shape error of 0.02 mm. Concerning a plate thickness of 0.3 mm, the maximum deviation rate was found to be 6.7%, which represents a 30% improvement over traditional stamping processes. The maximum wall thinning rate was found to be 3.3%, a 1% reduction compared to traditional stamping processes, confirming the process's feasibility. [ABSTRACT FROM AUTHOR]

Machining is a process that involves intense heat generation at localized points within the tool-chip interface. This leads to elevated temperatures, which can be detrimental to cutting tools. This issue becomes even more crucial when dealing with superalloys like Inconel 718, as they exhibit high shear strength and good creep resistance. Consequently, a significant amount of energy is expended, increasing the cutting temperature. Until now, the primary technique employed to address this issue has been using Cutting Fluids (CFs). In machining, a portion of costs is attributed to fluid handling. It also contains harmful elements that can pose health risks, potentially leading to conditions such as cancer. Moreover, the toxic components can contribute to environmental degradation when improperly disposed of. Therefore, this study proposes an innovative cooling technique called Internally Cooled Tools (ICTs). The ICTs employ an internally circulating coolant fluid through closed cooling channels within the cutting tools, eliminating fluid dispersion into the atmosphere. The main objective was to compare the performance of ICTs in controlling the tool-chip interface temperature during Inconel 718 turning using hard metal tools. For this purpose, a complete factorial experimental design (25) was utilized, with the response variable being the temperature measured by the tool-work thermocouples technique. Beyond that, a sustainable assessment was performed using the Pugh Matrix method. Many key sustainable factors were evaluated related to three atmospheres, cutting fluids in abundance – CFA, dry machining, and ICT. The data base used was a depth literature investigation together with results found in this work. The main findings of this entire work demonstrated that an increase in cutting parameters corresponded to an increase in temperature, as anticipated. TiNAl coating reduced the temperature by up to 10% compared to uncoated tools. Similarly, applying ICTs led to temperature reductions of up to 17% compared to dry machining conditions. The Pugh Matrix made considering 12 factors showed that ICT (14 points) was the most sustainable lubri-cooling method in comparison to CFA (3) and DM (5). Ultimately, ICTs showed to be a promising eco-friendly method. It outperformed conventional methods, showcasing a remarkable heat dissipation capacity. As a result, further studies are warranted to delve deeper into this promising approach. [ABSTRACT FROM AUTHOR]

A novel γ–γ′ (Ni solid solution—Ni3Al) NiPtAl coating was produced on advanced single-crystal (SC) superalloy N5 by electroplating of a thin Pt coating with ~ 3 μm in thickness followed by heat treatment at 1000 °C in vacuum. For comparison, a traditional γ–γ′ NiPtAl coating was also produced by electroplating of a thick Pt coating with ~ 6 μm in thickness followed by heat treatment at 1100 °C in vacuum. The novel coating has a mass gain of ~ 0.5 mg·cm−2 after 100 h 1-h cyclic oxidation at 1150 °C, showing better oxidation resistance than the traditional coating. An oxide scale mostly consisting of α-Al2O3 grew on the novel coating because the element Cr from the SC alloy substrate contributes to the formation of α-Al2O3. Pt content in the novel coating has significant effect on the oxidation resistance. The optimized Pt content in the coating is about 16 at%, which is helpful to reduce the diffusion of harmful elements from the substrate into the coating but also to reduce the cost of the coating. [ABSTRACT FROM AUTHOR]

This study investigates the surface topography of microfinishing abrasive films and their machining capability on the Nimonic 80A superalloy, a high-performance nickel-based alloy commonly used in aerospace and gas turbine engine applications. Surface analysis was conducted on three abrasive films with nominal grain sizes of 30, 15, and 9 μm, exploring wear patterns, contact frequency, and distribution. To assess the distribution of grain apexes, Voronoi cells were employed. Results revealed distinct wear mechanisms, including torn abrasive grains and cracked bond surfaces, highlighting the importance of efficient chip removal mechanisms in microfinishing processes. Larger grain sizes exhibited fewer contacts with the workpiece but provided more storage space for machining products, while smaller grain sizes facilitated smoother surface finishes. The research demonstrated the effectiveness of microfinishing abrasive films in reducing surface irregularities. Additionally, surface analysis of worn abrasive tools provided insights into wear mechanisms and chip formation, with the segmentation of microchips contributing to efficient chip removal. These findings underscore the significance of selecting appropriate abrasive films and implementing effective chip removal mechanisms to optimize microfinishing processes and improve surface finishing quality in advanced material machining applications. It is worth emphasizing that no prior research has investigated the microfinishing of components crafted from Nimonic 80A utilizing abrasive films, rendering this study truly unique in its contribution to the field. [ABSTRACT FROM AUTHOR]

Aero-engines can be exposed to One Engine Inoperative (OEI) conditions during service, and the resulting overheating effect may significantly impact their structural integrity and flight safety. This paper focuses on the influence of overheating on the microstructural evolution and tensile properties of the GH4720Li alloy, a nickel-based polycrystalline superalloy commonly used in turbine disks. Based on the typical OEI operating conditions of a real aero-engine, a series of non-isothermal high-temperature tensile tests involving an OEI stage of 800 °C were conducted. The effects of OEI-induced overheating on the microstructure and tensile properties of the GH4720Li alloy were investigated. The results showed that, after OEI treatment, the primary γ′ phase in this alloy was partially dissolved. The GH4720Li superalloy also exhibited numerous microcracks at the grain boundaries, resulting in complex effects on its tensile properties. The alloy's yield strength and ultimate tensile strength were slightly decreased, whereas its ductility decreased considerably. The OEI-induced embrittlement phenomenon was mainly caused by the non-uniform distribution of the tertiary γ′ phase within grains. The formation of microcracks nucleated at the interfaces between the primary γ′ precipitates and γ matrix phase was another key factor. [ABSTRACT FROM AUTHOR]

The precipitation-hardenable nickel-based superalloy Rene 41 exhibits remarkable mechanical characteristics and high corrosion resistance at high temperatures, properties that allow it to be used in high-end applications. This research paper presents findings on the influence of thermal shocks on its microstructure, hardness, and thermal diffusivity at temperatures between 700 and 1000 °C. Solar energy was used for cyclic thermal shock tests. The samples were characterized using microhardness measurements, optical microscopic analysis, scanning electron microscopy coupled with EDS elemental chemical analysis, X-ray diffraction, and flash thermal diffusivity measurements. Structural transformations and the variation of properties were observed with an increase in the number of shocks applied at the same temperature and with temperature variation for the same number of thermal shocks. [ABSTRACT FROM AUTHOR]

In this study, In718 powder mixtures prepared from elemental powders following stoichiometric composition and supplied as a commercial product were produced by conventional powder metallurgy (1300 °C/4 h) and electric current-assisted sintering (ECAS)(1700-2300A/10 min) methods and followed by a double-aging heat treatment. The characterization studies determined that the best results were the sample produced by the ECAS method using the elemental powder mixture. The targeted precipitate γ′, γ″, and δ phases were obtained after the heat treatment, and a hardness value of 344 ± 41 HV0.5 and a relative density of 98.96% were achieved. The sample preserved its surface integrity by exhibiting high corrosion resistance from hot corrosion studies in the temperature range of 650–850 °C and NaSO4 + 60%V2O5 environment. The corrosion rate of the sample, which was subjected to electrochemical corrosion tests in 3.5% NaCl and 10% NaNO3 solutions, was determined as 45.59 mpy and 10.56 mpy, respectively. [ABSTRACT FROM AUTHOR]

To optimize the hot deformation microstructure of the difficult-to-deform GH4975 superalloy, this study investigates the effect of cooling rate after sup-solvus temperature holding on the initial microstructure before hot deformation, and the effect of initial microstructure difference on the hot deformation microstructure. The results indicate that with decreasing the cooling rate from 1 to 0.1 °C min−1, the γ′ precipitates evolve into big size and irregular shape gradually, and the ratio of volume fraction to size of γ′ precipitates decreases. These changes intensify the bulging of grain boundaries (GBs) and enhance the migration of dislocations and GBs in γ matrix. Therefore, the nucleation and development of dynamic recrystallization (DRX) grains in γ matrix during deformation are promoted, but the refinement effect of DRX grains in γ matrix is weakened. Noteworthily, there is a transition point when the cooling rate is extremely slow so that the fully grown γ′ precipitates can contact each other and separate or seal off the local γ matrix. The DRX grains in γ matrix cannot penetrate the envelope of γ′ precipitates and undergo significant refinement. Moreover, these large and irregular γ′ precipitates are fragmented into chains during deformation, undergo DRX, and eventually become refined. This is to say, sup-solvus temperature holding (1220 °C for 10 h) followed by extremely slow cooling (0.1 °C min−1) can not only ensure high DRX fraction, but also ensure fine grains of deformed microstructure, which is a recommended pretreatment process. [ABSTRACT FROM AUTHOR]

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The main features of superalloys are included good stability and strength at high temperatures (excellent mechanical strength), creep resistance at high temperatures, resistance to corrosion and oxidation at high operating temperatures, and resistance to thermal deformation at high operating temperatures. Superalloys have different properties, meaning that each alloy has its unique chemical and mechanical properties, so it is necessary to find the physical, mechanical, and chemical properties of superalloys. There are several ways to do this: The experimental method, computational and analytical method, and molecular dynamics simulation method. In this research, Mechanical properties of superalloys have been studied using molecular dynamics simulation. Tensile-pressure behavior of the superalloys, dislocations, hardness behavior, elastic-plastic behavior, crack growth, fatigue properties, and creep behavior have been considered. Eventually, some challenges and future work will be discussed. [ABSTRACT FROM AUTHOR]

Carbon nanofibers (CNFs) and graphene nanosheets (GNs) are introduced to obtain nano-sized TiC particles in a novel additive manufactured Ni-Co-based superalloy. The double strengthening effects of reaction-induced TiC and remaining CNFs/GNs are conceptualized in the present paper. The CNFs and GNs act as heterogeneous nucleation sites for the formation of uniformly distributed TiC nanoparticles, which inhibits the crack and homogenize the microstructure. Interestingly, the existence of remaining GNs/CNFs is revealed via 3D atom-by-atom tomographic reconstruction technology for the first time. This unique combination of nanoparticles and residual CNFs/GNs nanofillers has great potential to develop superalloys with excellent properties. The formation of nano-sized dispersion TiC particles is induced by the introduction of carbon nanofibers and graphene nanosheets in additive manufactured superalloy, which inhibits the crack and homogenizes the microstructure. [ABSTRACT FROM AUTHOR]

The study investigates the effects of oxygen-sulfur content, holding temperature, and time on the wettability and interfacial reactions between DD5 superalloy and Al2O3-based ceramic shells through non-in-situ sessile drop experiments. Lowering the oxygen-sulfur content in the DD5 master alloy, as well as reducing the holding temperature and time, leads to an increase in the wetting angle and a mitigation of interfacial reactions. Improved wettability promotes interfacial reactions, while intensified interfacial reactions further spread the alloy melt, enhancing its wettability. The main products of the interfacial reaction between the DD5 alloy and Al2O3-based ceramic shells are Al2O3 and Si, with the process being influenced by the presence of Al. When the oxygen-sulfur content is controlled within 6 ppmw, the wettability will undergo a characteristic transformation, resulting in a sharp increase in the wetting angle. It demonstrates that the ultra-pure DD5 master alloy plays a crucial role in reducing wettability and interfacial reaction, as well as slowing down the tendency of the hetero-crystal formation. Therefore, it is of great engineering significance to further reduce the content of oxygen-sulfur impurity elements in DD5 superalloy.