Abstract
The gradient structures in surface layer of single-crystal nickel alloy (SX alloy) were produced (i.e., nanograin, submicron grain and coarse single crystal of bulk material) by means of ultrasonic-assisted high-speed grinding (UAHSG). The surface layer with a grain size gradient (from 29.7 to 111.8 nm) along depth from the treated surface featured impressive nano-indentation hardness (up to 12.1 GPa) beyond the initial SX alloy. The coupled effects of high rotation speed of abrasive grain (100 m/s) and the severe ultrasonic vibration impact (up to 4.3 times per contact cycle) induced large strain (up to 6.67) and ultrahigh strain rate (∼109 s−1), resulting in the superiority of such a structure gradient. This study suggests a new approach of UAHSG that can not only achieve high machining efficiency, but also make nickel alloy stronger by tailoring the surface layer gradient structures.
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