Deformation and failure mechanisms of single crystal superalloy under temperature gradient

The crystallographic constitutive model under temperature gradient is developed and introduced to study the deformation and failure mechanisms of single crystal superalloy. Tensile tests of thin-walled pipe specimen at different temperatures without cooled air flow were carried out. Based on the experimental results, the temperature dependence of constitutive model was studied and the basic parameters of constitutive model were obtained. To investigate the deformation and failure mechanisms, the thin-walled pipe specimen with cooled air flow under temperature gradient were tested. Considered the fluid-solid interface (FSI), a finite element method (FEM) was proposed to simulate the process of tension. In FEM, the activation rate of slip system was defined as the failure law of specimen under temperature gradient. The simulation result was in good agreement with the experiment result. Furthermore, the fracture surface of the specimen was observed by the scanning electron microscopy (SEM). The microstructure revealed that the slip deformation belonged to {1 1 1} crystalplane is a principal failure mechanism of single crystal superalloy under temperature gradient. The results of the SEM also implied that the proposed FEM method can be used to systemically study the deformation and failure behavior of single crystal superalloy cooled blade.     

Crystal plasticity and multiscale modelling of superalloy creep

A crystal plasticity approach for superalloy creep has been presented which employs a finite element-based representative volume element (RVE) methodology. The γ channels are assumed to undergo crystal slip and the γ′ particles to deform elastically. A range of superalloys has been studied. Thermocalc computations provide the γ′ volume fraction and an automated scheme for generating the resulting RVE has been developed. It has been shown that primary creep response in a wide range of superalloys over high stress, low temperature regimes is represented excellently by the model, by determination of just an activation energy and an alloying element density. It has been hypothesised that the transition from primary to secondary creep results from the development of geometrically necessary dislocations within the γ channels at the γ′ interfaces. Without the need of further material parameters, it has been shown that secondary creep rates over a broad range of stress and temperature can be accurately predicted, hence supporting the hypothesis. An empirical relationship has been established between the alloying element density and the atomic weight percentages of the alloying elements, using a range of superalloy data. It is hypothesised that a role of the alloying elements within the γ channels is to act as inhibitors of ribbon dislocation motion, hence leading to the large range of macro-level primary and secondary creep responses observed in the alloys with variations in constituent alloys. The empirical relationship established, when combined with the crystal RVE methodology, then allows the prediction of superalloy creep rates from knowledge of alloying constituents.     

The key role of dislocation dissociation in the plastic behaviour of single crystal nickel-based superalloy with low stacking fault energy: Three-dimensional discrete dislocation dynamics modelling

To model the deformation of single crystal nickel based superalloys (SCNBS) with low stacking fault energy (SFE), three-dimensional discrete dislocation dynamics (3D-DDD) is extended by incorporating dislocation dissociation mechanism. The present 3D-DDD simulations show that, consistent with the existing TEM observation, the leading partial can enter the matrix channel efficiently while the trailing partial can hardly glide into it when the dislocation dissociation is taken into account. To determine whether the dislocation dissociation can occur or not, a critical percolation stress (CPS) based criterion is suggested. According to this CPS criterion, for SCNBS there exists a critical matrix channel width. When the channel width is lower than this critical value, the dislocation tends to dissociate into an extended configuration and vice versa. To clarify the influence of dislocation dissociation on CPS, the classical Orowan formula is improved by incorporating the SFE. Moreover, the present 3D-DDD simulations also show that the yielding stress of SCNBSs with low SFE may be overestimated up to 30% if the dislocation dissociation is ignored. With dislocation dissociation being considered, the size effect due to the width of γ matrix channel and the length of γ′ precipitates on the stress–strain responses of SCNBS can be enhanced remarkably. In addition, due to the strong constraint effect by the two-phase microstructure in SCNBS, the configuration of formed junctions is quite different from that in single phase crystals such as Cu. The present results not only provide clear understanding of the two-phase microstructure levelled microplastic mechanisms in SCNBSs with low SFE, but also help to develop new continuum-levelled constitutive laws for SCNBSs.     

电感耦合等离子体光谱法测定镍基高温合金中的硅、锰、磷

建立了电感耦合等离子体光谱测定镍基高温合金中硅、锰、磷元素的方法,优化了试样前处理方法,对前处理所用酸的酸度进行不同比例试验,确定了仪器测量条件及分析谱线.在一定浓度范围内,各元素的浓度与谱线强度呈线性关系,相关系数大于0.9999.加标回收率为93.3%～106.7%,测定结果的相对标准偏差小于3.0%(n=10)....     

Three-dimensional microstructure simulation of Ni-based superalloy investment castings

An integrated macro and micro multi-scale model for the three-dimensional microstructure simulation of Ni-based superalloy investment castings was developed, and applied to industrial castings to investigate grain evolution during solidification. A ray tracing method was used to deal with the complex heat radiation transfer. The microstructure evolution was simulated based on the Modified Cellular Automaton method, which was coupled with three-dimensional nested macro and micro grids. Experiments for Ni-bas...     

A coupled elastoplastic-damage constitutive model with Lode angle dependent failure criterion

A coupled elastoplastic-damage constitutive model with Lode angle dependent failure criterion for high strain and ballistic applications is presented. A Lode angle dependent function is added to the equivalent plastic strain to failure definition of the Johnson–Cook failure criterion. The weakening in the elastic law and in the Johnson–Cook-like constitutive relation implicitly introduces the Lode angle dependency in the elastoplastic behaviour. The material model is calibrated for precipitation hardened Inconel 718 nickel-base superalloy. The combination of a Lode angle dependent failure criterion with weakened constitutive equations is proven to predict fracture patterns of the mechanical tests performed and provide reliable results. Additionally, the mesh size dependency on the prediction of the fracture patterns was studied, showing that was crucial to predict such patterns.     

高通量微区扫描EDXRF仪器设计

用多毛细管X射线透镜做光源的微区扫描型EDXRF仪器,围绕出射焦斑对称放置4～6个SDD探测器,设计软件控制X射线管、多个探测器、高精度移动平台,同时进行数据采集、信号同步和结果分析,从而开发完成NX-mapping高通量微区扫描型EDXRF仪器。由于多探测器的采用,该仪器的信号强度得到数倍的提升,且稳定性没有因为器件间的差异而变差,同等条件,同等用时的情况下,测试标准偏差降为单探测器时的不足40%。均匀样品2 mm×2 mm面扫描时,400个点的测试标准偏差与定点测试无差异,说明运动机构和控制算法表现优异,不会对测试结果产生影响。对于微区扫描仪器的焦斑尺寸,用“荧光刀口实验”的方法,对Fe,Ni和Mo元素进行了测试,测得三种元素的有效焦斑尺寸最小值分别为52.4,49.3和39.03 μm,各元素有效焦斑尺寸随原子序数的增加而减小,这与多毛细管X射线透镜的设计原理相符;实验还发现了各元素焦斑有效尺寸在极小值处对高度变化较为敏感的规律,因此建议为了得到统一清晰的扫描图像,要保持样品表面的平整。最后用NX-mapping仪器对某单晶高温合金样品的Ni,Ta,W和Re元素进行扫描和分布分析,图像清晰,枝晶结构明显可辨,并且其中Ni∶Ka特征线强度高达220 kcps,明显高于普通的XRF测试。在NX-mapping微区扫描型EDXRF仪器中,由于多探测器的采用,信号强度高,测试精密度好,随之测试时间可以缩短,因此可以满足高通量测试的需求。     

喷射成形粉末高温合金FGH4095M的制备及组织特征

喷射成形是一种近净成形的在粉末冶金气体雾化制粉技术基础上发展起来的快速凝固技术. 本文采用喷射成形技术制备成分优化后的FGH4095M合金, 研究了喷射成形FGH4095M合金沉积坯的致密度、显微组织特征, 特别是研究了喷射成形高温合金组织中特殊形貌的γ’相. 研究表明, 致密度与沉积坯部位有关, 底部致密度最高, 可达99.63%, 热等静压后的致密度可达100%. 喷射成形合金组织以均匀细小的等轴晶为主, 不存在原始颗粒边界; 一次γ’ 相尺寸约为0.6-0.8 μm, 二次γ’相尺寸约为0.1-0.5 μm, 在二次γ’相的间隙中有少量尺寸约为10-20 nm的三次γ’相. 喷射成形FGH4095M 合金中的二次 γ’相中出现特殊形貌的γ’相, 这是由单个γ’颗粒分裂形成, 与沉积过程的低冷却速度有关. 分裂过程是γ’颗粒总能量降低的过程, γ’颗粒间的弹性交互作用能起到主导作用. 对分裂γ’相的等效直径进行统计, 得到γ’ 相等效直径超过0.40 μm 后, 会出现分裂趋势. 合金具备优异的拉伸性能, 室温塑性得到显著提高, 出现γ’ 相分裂的特殊形貌组织是否对合金性能的提高产生直接影响仍需进行进一步的研究.     

A coupled kinetic-constitutive approach to the study of high temperature crack initiation in single crystal nickel-base superalloys

A rate-dependent crystallographic constitutive theory coupled with a mass diffusion model has been used to study crack initiation in single crystal nickel-base superalloys, exposed to an oxidising environment and subjected to mechanical loading. The time to crack initiation under constant load has been predicted using a strain-based failure criterion. A notched compact tension (CT) specimen containing a single casting defect, idealised as a cylindrical void close to the notch surface, has been studied. Finite element analysis of the CT specimen revealed that, due to the strong localisation of inelastic strain at the void, a microcrack will initiate in the vicinity of the void rather than at the notch surface. The numerical results have also shown that the time to crack initiation depends strongly on the void location. The coupled diffusion-deformation studies have revealed that environmental effects reduce the time to crack initiation due to the oxidation-induced material softening in the vicinity of the notch and void. The applicability of a failure assessment approach, based on the linear elastic stress intensity factor, K, to predict the crack initiation time under creep loading is examined and a probabilistic framework for prediction of component lifetime is proposed.     

电感耦合等离子体原子发射光谱法测定高温合金中低含量钇

建立电感耦合等离子体原子发射光谱法测定高温合金中低含量钇的方法。采用盐酸、硝酸、氢氟酸溶解样品,在优化的仪器条件下,采用基体匹配法配制系列标准工作溶液,选择分析线为360.073 nm。钇的含量在0.0005%~0.050%范围内与光谱强度具有良好的线性关系,相关系数为0.99999,检出限为0.000003%。该方法测定结果的相对标准偏差不大于6.0%(n=8),加标回收率为90.0%~104.0%。该方法简便、快速、准确,可用于高温合金中低含量钇的测定。