Effect of Thermal Annealing on Machining-Induced Residual Stresses in Inconel 718

Abstract

Nickel-based alloys are widely employed in the manufacturing of aero-engines. These alloys are difficult to machine, and tensile residual stresses are generated during machining. These tensile residual stresses can negatively affect the performance of aero-engine components. Nevertheless, residual stresses can vary due to thermal or mechanical loading. These variations must be considered to evaluate the real influence of residual stresses on component behavior. This paper studies the effect of thermal loads on machining-induced residual stresses in the alloy Inconel 718. A ring-shaped Inconel 718 part was face-turned, and specimens were extracted from it. Specimens were exposed at 550 and 650 °C for 10 min, 1 and 10 h. Residual stresses were measured, and microstructure was observed before and after thermal exposure. Residual stress variations found after thermal exposure were the consequence of two factors: relaxation of strain bands during the early stage of exposure and diffusion-controlled creep. In addition, a modified Zener-Wert-Avrami model is proposed to predict residual stress relaxation caused by the diffusion-controlled creep. Once having fitted the modified Zener-Wert-Avrami model, the study was extended for a wider range of temperatures (400-650 °C). This analysis showed that surface residual stresses do not relax significantly at temperatures below 500 °C.