G. Mrówka-Nowotnik

Development of Nickel Based Superalloys for Advanced Turbine Engines

Superalloys have been developed for specific, dedicated properties and applications. One of the main application for this material is advanced, high-performance aircraft engines elements. Turbine engine creates harsh environments for materials due to the high operating temperature and stress level. Hence, as described in this article, many alloys used in the turbine section of these engines are very complex and highly optimized. This article provides an overview of structural changes that occur during the aging process of wrought and cast alloys and provides insight into the use of precipitated particles to achieve desired structures. Example will focus on alloy Inconel 718 and CMSX-4. Functional properties of these alloys can be achieved by choosing proper heat treatment parameters to obtain required rate between secondary phases. The paper also attempts to determine structural perfection and changes of crystallographic orientation along the axis of growth of single crystal nickel superalloys cast using X-ray topography and Laue diffraction method. Single crystal bars and turbine blades were manufactured in VIM furnace using the Bridgeman method. Withdrawing rates typical for CMSX-4 superalloy were used. It has been found that with increasing withdrawing rate the nature of distribution along the axis of growth of the angle of [001] direction deviation from the axis of single crystal blades growth had changed. The change of the withdrawing rate results also in the rotation of γ’ phase in the form of cubes against the axis of single crystal blades growth.

Dynamic precipitation of nickel-based superalloys undergoing severe deformation below the solvus temperature

Abstract The authors performed uniaxial compression tests of nickel-based superalloys: single crystal CMSX–4, also precipitation hardened; Inconel 718 and X750, at temperatures below the γ′ solvus, in order to study the effect of temperature and strain rate on their flow stress and microstructural development. On the basis of the obtained flow stress values, the activation energy of a high-temperature deformation process was estimated. Microstructural observations of the deformed samples at high temperatures, previously solution heat treated and aged CMSX–4 and Inconel alloys revealed non-uniform deformation effects. Distribution of either molybdenum- or niobium-rich carbides was found to be affected by localized flow within the investigated strain range at relatively low deformation temperatures, 720–850 °C. Microstructural examination of the alloys also showed that shear banding and cavity growth were responsible for the decrease in flow stress and a specimen fracture at larger strains.

The chemical phenol extraction of intermetallic particles from casting AlSi5Cu1Mg alloy

This paper presents a chemical extraction technique for determination of intermetallic phases formed in the casting AlSi5Cu1Mg aluminium alloy. Commercial aluminium alloys contain a wide range of intermetallic particles that are formed during casting, homogenization and thermomechanical processing. During solidification, particles of intermetallics are dispersed in interdendritic spaces as fine primary phases. Coarse intermetallic compounds that are formed in this aluminium alloy are characterized by unique atomic arrangement (crystallographic structure), morphology, stability, physical and mechanical properties. The volume fraction, chemistry and morphology of the intermetallics significantly affect properties and material behaviour during thermomechanical processing. Therefore, accurate determination of intermetallics is essential to understand and control microstructural evolution in Al alloys. Thus, in this paper it is shown that chemical phenol extraction method can be applied for precise qualitative evaluation. The results of optical light microscopy LOM, scanning electron microscopy SEM and X‐ray diffraction XRD analysis reveal that as‐cast AlSi5Cu1Mg alloy contains a wide range of intermetallic phases such as Al4Fe, γ‐ Al3FeSi, α‐Al8Fe2Si, β‐Al5FeSi, Al12FeMnSi.

Single-frequency induction hardeningof structural steel

Purpose: Current paper presents investigation of specimens after single frequency induction hardening process. The main aim is to compare microstructure of the material after the process conducted with different voltage on the induction coil. Moreover, two different steel grades are used for comparative reasons. As the final result it is desired to obtain sufficient parameters for the process in aim to obtain proper surface treatment of the material. Design/methodology/approach: The objectives of the research are achieved by using single-frequency induction hardening device with varying voltage. Two different steel grades were treated with change of the induction voltage from 300 to 600 V. Findings: In the outcomes of the study, the main conclusion is that there is an impact of the induction voltage in the hardening process on the microstructure of treated elements, both for 40H41Cr4 and 40HNMA36NiCrMo16 steels. Research limitations/implications: Obtained results will be used for much more complex investigation of the induction hardening process in future to introduce more exact parameters and double-frequency induction hardening process for complex geometries as gears. Originality/value: The originality of the research is based on the specific process and the materials that are being submitted to the comparative analysis. Moreover, executed research will be a basis for more complex induction hardening processes in the future.

Analysis of precipitation strengthening process in 2xxx aluminium alloys

This paper is showing the results of study devoted to determination of the chemical composition and strengthening process parameters effect on the precipitation sequence of intermetallic phases in the supersaturated 2xxx aluminium alloys. This study was based on a calorimetric study where temperature’s effects were determined when precipitation process occurred during heating with different heating rate of the supersaturated alloys group of 2xxx. Based on the calorimetric curves and estimated values of ln(Q/T2) and 1000/RT an activation energy for precipitation and dissolution of phase components were evaluated.

Analysis of Intermetallic Phases in 2024 Aluminium Alloy

The main objective of this study was to analyze the evolution of the microstructure (morphology, composition and distribution of intermetallic phases) in the 2024 aluminium alloy cooled with different cooling rates after solidification process. A few techniques: optical light microscopy (LM), scanning (SEM) electron microscopy combined with an energy dispersive X-ray microanalysis (EDS), X-ray diffraction (XRD) were used to identify intermetallics in the examined alloy. The results show that the microstructure of 2024 aluminum alloys in as-cast condition consisted following intermetallic phases: Al2Cu, Al2CuMg, Al7Cu2Fe, Al4Cu2Mg8Si7, AlCuFeMnSi and Mg2Si.

Mechanical Aspects of Plastic Deformation of Nickel Based Superalloy

Variations of a true stress vs. true strain illustrate behaviour of materials during plastic deformation. Stress-strain relationship is generally evaluated by a torsion, compression and tensile tests. Results of these tests provide crucial information pertaining to the stress values which are necessary to run deformation process at specified temperature and cooling rate. Uniaxial compression tests at temperatures below the γ solvus were conducted on nickel based superalloy CMSX-4, to study the effect of temperature and strain rate on its flow stress. On the basis of received flow stress values activation energy of a high-temperature deformation process was estimated. Mathematical dependences (σpl -T i σpl - ἐ) and compression data were used to determine material constants. These constants allow to derive a formula that describes the relationship between strain rate, deformation temperature and true stress.

Transformation of Intermetallic Phases in 6066 Aluminium Alloy during its Homogenization

The effect of temperature and time of homogenization on intermetallic phase dissolution and transformation in 6066 alloy was studied. Microstructure examination has been carried out on the samples in the as-cast state and after different time of homogenization at 560°C using optical microscope - Nikon 300, scanning (SEM) electron microscopy combined with an energy dispersive X-ray microanalysis (EDS) and X-ray diffraction (XRD). The results show that the as-cast microstructure of 6066 contained β-Mg2Si, Si, Q-Al5Cu2Mg8Si6, b-Al5FeSi, α-Al(MnFe)Si and Al2Cu intermetallic phases. Significant changes in microstructure followed after homogenization process were revealed. The majority of Al2Cu, Q and Mg2Si particles have dissolved in a-Al, and plate-like b-Al5FeSi precipitates transformed into multiple, spherical α-Al(MnFe)Si.

Discontinuous transformation in the steel under hot deformation conditions

Purposeful effect of hot deformation process and transformation – austenite (A) to ferrite (F) and to pearlite (P) – interaction on the carbon steel microstructure was studied. Hot compression tests at various strain rates were performed during controlled cooling of the sample within the temperature range related to the start and finish of the phase transformation. Attention was paid to structural effects of dynamic precipitation and resulted morphology of structural components depended on expected localisation of phase transformation. The findings of carbide precipitates development along ferrite grain boundaries was the most noticeable effect of the hot deformation and subsequent transformation for tested samples. However, the flow localisation and preferred growth of the discontinuous transformation product-pearlite at shear bands was very limited. [Received on 25 October 2006; Accepted on 21 February 2007]