Hastelloy C-276 Research Articles

Application of minimum quantity GnP nanofluid and cryogenic LN2 in the machining of Hastelloy C276

The current study delves into the combined influence of lubrication and cooling on the machinability of a difficult-to-cut superalloy. A comparative study of four lubricating mediums—dry, Minimum Quantity Lubrication (MQL), nanoMQL (NMQL), and Cryo-NMQL—was conducted during the milling of Hastelloy C276. Findings reveal that the Cryo-NMQL medium resulted in a 25.49%, 29.84%, and 42.50% decrease in cutting force, cutting temperature, and surface roughness, respectively, compared to dry cutting. This lubricating medium also decreased tool wear by 44.55%, as confirmed by SEM images showing reduced adhesion and abrasion. Analysis of chip morphology indicated a finer lamella structure with minimal serration under Cryo-NMQL, indicating enhanced efficiency. Furthermore, Cryo-NMQL refined the grain structure, enhancing microhardness for improved superalloy machining. ANOVA analysis identified feed rate and cutting speed as the most impactful parameters affecting the machining responses. Lastly, based on MORSM analysis, optimal machining parameters were determined as a cutting speed of 76.60 m/min, feed rate of 0.12 mm/tooth, radial depth of cut of 6.7 mm, and axial depth of cut of 0.6 mm. Experimental and predicted values closely matched, with a composite desirability score of 0.912, showcasing the efficacy of MORSM in addressing machining difficulties. This holistic investigation underscores Cryo-NMQL as a promising solution for the efficient and effective machining of superalloys.

Crystallographic texture and multiscale boundaries mediated creep anisotropy in additively manufactured Ni-based Hastelloy C276 superalloy

The microstructure and high-temperature creep mechanisms of Ni-based Hastelloy C276 superalloy fabricated using wire and arc-based directed energy deposition were investigated systematically and innovatively. The microstructural investigation revealed that the as-fabricated samples comprise γ-Ni matrix and topologically close-packed (TCP) P phase precipitates. The γ matrix subgrains and grains are spread over multiple highly textured columnar dendrites, with a majority of γ <001> crystallographic orientations closely aligned along the deposition direction. Moreover, the interdendritic regions exhibit severe Mo segregation, P phase particles, and dislocation bands. Creep tests were conducted on miniature samples under various temperature and stress conditions, loaded either in the deposition direction (DD) or travel direction (TD). DD samples exhibit lower minimum strain rates, greater strains-to-failure, and longer creep rupture lifetimes than TD samples, indicating significant creep anisotropy. Dislocation creep was identified as the primary creep mechanism for both DD and TD conditions. During creep, dynamic precipitation of TCP phases occurred in the interdendritic regions, resulting in varying creep resistance between interdendritic and dendritic core regions. Isostress and isostrain models, considering both crystallographic texture and precipitation strengthening, reasonably predicted the observed creep anisotropy during the secondary creep stage. Additionally, variations in the Schmid factor led to significant deformation incompatibility among dendrites in TD samples. Dislocation accumulation in TD sample interdendritic regions promoted new grain nucleation, triggering dynamic recrystallisation, facilitating grain boundary sliding, and accelerating tertiary creep. Furthermore, TCP phase particles in the interdendritic regions contributed to microcrack development, further accelerating creep fracture, especially in the TD condition.

Sensitivity analysis on surface topography for laser-surface-texturing of Hastelloy C-276 superalloy: studies on micro-structure morphology characterization

Sensitivity analysis on surface topography for laser-surface-texturing of Hastelloy C-276 superalloy: studies on micro-structure morphology characterization

Multi-Objective Parametric Optimization of Micro-Electro Discharge Machining of Hastelloy C276 Super Alloy Using Response Surface Methodology and Particle Swarm Optimization

The need for the application of superalloys in aerospace industries in recent years has increased owing to its benefits such as extensive load-bearing capability under high temperatures. Hastelloy is one such superalloy that is extensively utilized in the aerospace sector because of its good corrosion and heat resistance among the other nickel-based superalloys. In this work, the investigation is conducted to understand the effects of input process parameters such as voltage, pulse off time (Toff), and pulse on time (Ton) on the response variables, namely Material removal rate (MRR), Tool wear rate (TWR), Overcut (OC), and Taper Ratio (TR) during micro-EDM of Hastelloy C276. For micro drilling the Hastelloy C276 material, a copper electrode with a diameter of 0.5 mm is utilized. To investigate the connections between the input and output characteristics, a technique known as the Response Surface Methodology (RSM), which is a collection of mathematical and statistical methodologies, is applied. The experimental runs are carried out with the help of the RSM-based Box-Behnken design (BBD). The experimental outcomes were computed, and ANOVA was used to identify the most influential variables. In addition, particle swarm optimization (PSO) was utilized to optimize the results, which were compared to the Response surface methodology approach. The outcomes of the PSO-optimized results revealed a strong correlation between expected and experimental outcomes over the RSM approach.

Some studies on optimization of process parameters for wire ARC additive manufacturing of Hastelloy C276 using GRA-GWO hybrid techniques

Wire arc additive manufacturing (WAAM) has become an inevitable manufacturing technology in the present decade. This article discusses optimizing process variables for fabricating Hastelloy C276 alloy via WAAM. The controlling parameters are gas flow rate (GFR), deposition speed, and welding current, while the depth of penetration, top reinforcement, and bead width are the output parameters considered for optimization. The magnitude of interaction effects between control parameters is equal to that of individual impact on the weld bead characteristics evident from analysis of variance results. Grey relational analysis revealed the optimal parameters (trial 1 with I = 120 A, S = 200 mm/min, GFR = 15 L/min) chosen through its robust optimization procedure. S/N ratio analysis revealed the most influencing parameters at the factor level (current level 1, speed level 1). The Grey Wolf optimizer (GWO) algorithm was used as a precision and confirmation experiment. The GWO optimization results further confirmed that the GFR of 15 L/min, speed of 200 mm/min, and current of 120 A were the optimized parameters used in this design space. Further, normal probability plots with minimal error of around 1% reinforce that the parameters chosen in this design space are well within the optimal limits. The surface plots reported the relationship and variation between control and resulting factors.

Effect of Laser Surface Modification on Texture, Roughness, Wettability and Surface Energy of Hastelloy C22, C276 &amp;amp; X

Hastelloy is a nickel-chromium-molybdenum-iron-based alloy and a member of the ‘superalloy’ family. Hastelloy has exceptional properties like high strength, wear resistance and high-temperature stress-corrosion resistance. Therefore, Hastelloy is used in gas turbines, power plants, metal injection molding, etc. Many industrial applications are related to the properties of the surface. Wettability is a key surface property that affects applications like lubrication, adhesion, coating, heat conduction, etc. Laser Texturing is an excellent method to modify the surface properties of materials like metal, polymers and ceramic. In the present study, a carbon dioxide laser created unidirectional textures on Hastelloy (C22, C276, X). Different sets of unidirectional textures were formed by changing the laser power and frequency. Various roughness parameters were compared for every laser parameter. In this paper, the effective change in wettability properties of Hastelloy (C22, C276, X) after the Laser texturing process for a range of power and frequency were studied under DI water and glycerol as test fluids. Results show that the contact angle of the test fluid increases as the laser power increases, and the contact angle decreases as the laser frequency increases for all three superalloys. The surface energy of a given set of samples was also measured using the recorded contact angle of DI water and Glycerol by the OWRK equation. Similar trends were found in surface energy for all three Hastelloy.

Welding investigation of Hastelloy C-276 and parametric optimization using integrated MRA-TLBO algorithm during A-TIG process

A-TIG welding is a modified form of GTAW process that has become popular due to its ability to create high-quality welded joints with minimal cracks and distortion. This technique is commonly used to join various metals, including stainless steel, aluminum, titanium, and nickel alloys like Hastelloy C-276, which is used in fabrication of complex components across marine, nuclear, aerospace, and chemical industries. In this investigation, A-TIG welding of Hastelloy C-276 was studied using three parameters - welding current, welding speed, and gas flow rate - at three distinct levels. The impact of these parameters were analyzed on two responses, namely penetration depth and width of weld. Macrostructural investigation, sensitivity analysis, and parametric studies revealed that welding current (I) had the most influence, followed by speed of welding (S) and flow rate of gas(G). Full quadratic multiple regression analysis-based models were developed for both responses, which were found to be suitable with a higher coefficient of determination and an average percentage error of 2.165% and 2.624%, respectively. Additionally, a teaching learning based optimization algorithm was integrated with these models to identify the most effective A-TIG parameter combination for higher penetration depth and lower weld width. The MRA-TLBO integrated approach resulted in an optimal parametric combination of I (170A), S (180 mm min−1), and G (11.37 l min−1) that resulted in a penetration depth and weld width of 4.503 mm and 4.684 mm, respectively. Validation at this optimal setting showed an improvement of 3.365% and 1.284% for weld width and penetration depth, respectively, suggesting the robustness of the developed methodology.

Study on mechanical and micro structural properties of spin arc welding in Hastelloy C-2000

Nickel-based Hastelloy C-2000 is widely used in the aerospace, chemical, and medicinal sectors. Investigating the potential efficacy of the spin arc welding process on Hastelloy C-2000 was the main focus of this study. In spin arc welding the centrifugal force has been obtained in the fusion zone, thus the weldbead quality increases. Weld current, rotating speed, and spin diameter are all separate parameters used in the welding procedure. The microstructural investigation was carried out using optical microscopy, X-Ray Diffraction (XRD), and field emission scanning electron microscopy (FESEM). The mechanical characteristics of the welded specimens were examined closely. Spin Arc Welding ultimate tensile strength (UTS), hardness value (HV), and impact experiments were compared to those of the Multi-pass Pulsed Current Gas Tungsten Arc welding method (MPCGTAW). In 27 tests, increasing the current and rotating speed resulted in greater penetration depth and weld height. The width of the weld was found to be a little high, with a spinning diameter of 2 mm. In comparison, samples 5 and 15 were found to have better hardness, tensile strength, and toughness, especially with suitable welding parameters such as current (120 I and 140 I), speed (1800 rpm), and spin diameter (2 mm and 3 mm). A microstructural study showed no grain segregation, contributing to the material’s increased hardness and tensile strength. The novel findings of the present study suggest that spin arc welding might be superior for various Hastelloy C-2000 connections that might have great applications in industries.

Comparative analysis of die-sinking EDM and near dry EDM for machining difficult-to-cut materials: Stainless Steel 316 and Hastelloy C276

Comparative analysis of die-sinking EDM and near dry EDM for machining difficult-to-cut materials: Stainless Steel 316 and Hastelloy C276

Edge cracking behavior of Y2O3 films based on the stress intensity factor

Hastelloy C-276 alloy is the preferred substrate for YBa2Cu3O7-δ (YBCO) coated conductors prepared by Ion-beam-assisted deposition (IBAD) route, but its surface is too rough to meet application requirements. Y(CH3COO)3·4H2O precursor solution has a low flattening efficiency, and its film edges are prone to crack formations. In this paper, a model for the stress intensity factor was established to study the effect of the presence of cracks on film stress. The simulation results showed that increasing the coating thickness reduced the overall stress, but increased the stress concentration at the crack. The larger bottom layer defects also made it easier for cracks to be generated. Then, 10-m long Hastelloy C-276/Y2O3 strips were prepared by colloidal-solution deposition planarization (CSDP), with an average surface roughness Rq of 0.427 and only 10 coating layers. This improved the flattening efficiency by 40 %, and a CeO2 layer with a good biaxial texture was finally prepared.

Numerical Simulation on Microwave Melting of Hastelloy C-276

Melting of metals is of utmost importance in the manufacturing industry as it is the primary manufacturing process to obtain the desired shape and size. microwave melting is a novel technique that uses electromagnetic wave radiation to heat materials. In the present work, the melting of Hastelloy C-276 inside a multimode microwave applicator operating at 2.45 GHz and 900 W input power, is explored in numerical and experimental. This results in a significant reduction in processing time and leads to lesser material wastage. The distribution of temperature, electric field, and resistive losses was analysed to understand the microwave melting of the Hastelloy C-276 sample. The study revealed that the melting time taken was ~440 seconds for microwave melting of Hastelloy C-276.

Low Reflection-Loss Thermal Barrier Coating on Hastelloy C276 for Radio Control Rocket Tip Nosecone Using Yttria-Stabilized Zirconia (YSZ) at Extreme Temperature

The nosecone tip during the launch process becomes the first part that experiences friction against the atmosphere so that heat is generated, which continues to increase over time. Therefore, the nosecone tip material must have high-temperature resistance, and the materials used must not interfere with the avionics and telemetry systems of the rocket. When the sounding rocket orbits at an altitude of 200-300 Km, the atmospheric environmental conditions also fluctuate, so the nose cone tip must also be able to adapt to this condition. The end of the nose cone must be protected with a high heat-resistant Thermal Barrier Coating (TBC) coating using Yttria Stabilized Zirconia (YSZ). YSZ modified with Al2O3 has impressive performance against high thermal by increasing the temperature resistance of the substrate to about 1200°C. In this paper, the experiment done for the first time using Hastelloy C276 coated with YSZ with thermal spray method has shown good performance. The pull of test results shows the highest bond tensile strength after heat exposure value at 23,04 MPa. And the thermal torch testing resulted in mass decreasing by 0.493 grams at 1200°C. The vector analyser also offers good performance reflection loss, valued at -0.324 dB at 10 GHz, and the thermal gravimetry of the material tip nose is 93,2% at 1200°C.

Effects of Different Die Metals on the Performance and Friction and Wear of Composite Materials during the Extrusion Process.

Extrusion technology is widely utilized in the rubber processing industry, with the extruder serving as the core equipment. As mixed rubber enters the extruder, it undergoes conveyance and plasticization, ultimately forming specific shapes and dimensions upon extrusion. The extruder head is a crucial component, playing a key role in achieving the final product's required size and shape. Factors such as its structure, materials, and manufacturing processes significantly impact the efficiency, product quality, and sustainability of the extrusion process. However, prolonged operation leads to severe wear of the extruder head, adversely affecting rubber product quality. Additionally, extruder head processing poses challenges, with maintenance and repair being complex procedures. Therefore, exploring a wear-resistant, long-lasting metal material for the extruder head without compromising mixed rubber performance is essential. This study focuses on severely worn extruder head metal materials, comparing wear levels after friction with STELLITE 6 alloy, Hastelloy C-276 alloy, 38CrMoAlA, and tungsten carbide with composite rubber. Results show that compared to the NR/BR composite material after Hastelloy C-276 alloy friction, rubber Payne effect increased by 4.4% (38CrMoAl), 3.2% (STELLITE 6), and 4.6% (tungsten carbide). Similarly, rubber dispersion decreased by 9.4% (38CrMoAl), 4.7% (STELLITE 6), and 9.8% (tungsten carbide). Rolling resistance increased by 18.1% (38CrMoAl), 16% (STELLITE 6), and 23.4% (tungsten carbide). Friction coefficient increased by 3.5% (38CrMoAl), 2.8% (STELLITE 6), and 4.3% (tungsten carbide). Wear volume increased by 39.3% (38CrMoAl), 45.3% (STELLITE 6), and 48.9% (tungsten carbide). Specifically, using Hastelloy C-276 alloy as the extruder head metal material yields the best NR/BR composite material dispersion, highest ten times tear strength, excellent anti-wet skid resistance, and minimum rolling resistance. Conversely, using the other alloys results in varying reductions in the physical and mechanical properties of NR/BR composite materials. This research is crucial for improving rubber product quality and extending extruder head lifespan.

EFFECT OF ELECTROCHEMICAL PROCESS PARAMETERS ON THE HASTELLOY C-276 ALLOY FOR MACHINING SPEED AND SURFACE-CORROSION FACTOR

Electrochemical micromachining (ECMM) is a well know for manufacturing hard-to-cut materials, e.g., nickel-based alloys, titanium alloys and metal-matrix composites. For this reason it finds application in aerospace, automobile and biomedical industries. In this research Hastelloy C-276 is used as a workpiece and stainless-steel electrode coated with polytetrafluoroethylene (PTFE) to avoid stray current. The effect of process parameters such as voltage, duty cycle and electrolyte concentration on the machining speed and the surface-corrosion factor were studied. The range of 9–11 V has an impact on the machining speed. The electrolyte concentration range of 25–35 g/L shows a linear increase in the machining speed and the surface-corrosion factor is found to be highest at 1.1449 for an electrolyte concentration of 15g/L. The surface roughness depth profile depicts the values of Rz, Rt, Ra are 16.3 µm, 99.1 µm and 1.90 µm, and 15.4 µm, 50.6 µm and 1.49 µm, respectively.

Microstructure development and cavitation erosion resistance enhancement of additive manufactured Hastelloy C276 alloy coating on martensitic stainless–steel via directed energy deposition

In this study, a Hastelloy C276 coating was prepared on a martensitic stainless-steel substrate using laser melting deposition, aiming at obtaining a coating with high resistance to cavitation erosion. The coating is up to 600 μm thick, and the grain morphology of the coating exhibits a progression from bottom to top, transitioning from cellular to columnar and ultimately to equiaxed grains. Additionally, the grains grow at a specific angle to the substrate plane, following the direction of the heat source. A 200 μm thick compositional mixing zone is formed at the interface of the substrate and the coating, in which the coating elements and substrate elements mutually permeate and form a stable metallurgical bond. The microhardness of the coating is measured as 334.4 HV0.05, signifying a substantial improvement of 33.2 % compared to the substrate. The cavitation erosion process of the coating can be classified into three stages: incubation, accumulation, and stabilization. The material spalling damage caused by cavitation erosion progresses in a fatigued manner, and the coating demonstrates considerably enhanced resistance to cavitation erosion compared to the substrate.

Analysis of machinability and sustainability aspects while machining Hastelloy C4 under sustainable cutting conditions

In recent years, developments in the defense, aerospace, and medical industries have significantly increased the expectations regarding material performances. In particular, the demand for materials that can withstand very high and/or very low temperatures and harsh mechanical/chemical conditions has increased. The superior qualities of superalloys can adequately meet this demand. However, the difficulties encountered in the machining of these alloys cause some burdens both ecologically and economically due to the use of cutting fluid. Therefore, the use of cost-friendly and sustainable cutting fluids in the production industry has a vital role, both in terms of machining performance and the environment. From this perspective, this paper focuses on the effects of various cutting environments, i.e., Dry, MQL, LN2, N2, CO2, Vortex, LN2 + MQL, N2 + MQL, CO2 + MQL, and Vortex +MQL on the machining performance of Ni-based C4 alloy. Additionally, it was aimed to reveal the effect of cooling/lubrication methods on sustainability by performing a sustainability analysis. Firstly, surface roughness, power consumption, tool wear and mechanisms, and cutting temperature were considered as performance characteristics. When examined in terms of machinability, Vortex + MQL gave the best result in terms of surface roughness and power consumption, while LN2 gave the best result in terms of cutting temperature. Then, a comprehensive sustainability analysis was carried out. As a result, the CESMO follows the order of Dry > MQL > LN2 > LN2 + MQL > CO2 > CO2 + MQL > N2 > N2 + MQL > Vortex > Vortex + MQL. While employing Vortex + MQL cutting condition, the CESMO decreased by about 11.37% as compared to Dry cutting condition. While using a combination of different sustainable lubrications or coolants, the overall carbon emissions decreased in the range of about 15–25% approximately as compared to the employment of the individual cutting conditions (i.e., coolant/lubricants).

Multi-Objective Optimization for Sustainable Machining of Hastelloy C-276 Using Evolutionary Algorithms

Multi-Objective Optimization for Sustainable Machining of Hastelloy C-276 Using Evolutionary Algorithms

Electrochemical and spectroscopic study on corrosion behavior of Ni-based alloys in chloride melts: Materials for an integral molten salt fast reactor

For the long-term operation of integral molten salt fast reactor safety, it is necessary to select structural materials with high corrosion resistance such as Ni-based alloys in high-temperature chlorides of specific composition. In this study, the corrosion behavior of Inconel 600, Inconel X750, Hastelloy C-276, and Incoloy 800, which are the candidates for the structural materials in NaCl-KCl-MgCl2 melt at 723 K and NaCl-CaCl2 melt with CeCl3 or LaCl3 at 873 K were investigated by electrochemical and spectroscopic analyses toward designing materials used in the integral molten salt fast reactor. The corrosion rates were estimated based on the elemental analysis of alloy surfaces by glow-discharge optical emission spectroscopy and the corrosion current density by linear polarization technique. It was found that the trend of corrosion rate for each alloy changed significantly depending on the composition of the chloride melts. The electrochemical behavior obtained from the linear polarization measurement and the impedance spectroscopy indicated that the cathodic reaction during the corrosion process was different among each melt. To discuss the effect of molten salt composition on corrosion behavior, the melt structure was investigated by high-temperature Raman spectroscopy and density functional theory calculation. The results indicated that the coordination structure of oxide ions, which are corrosion products formed in the cathodic reaction, changed depending on the composition of the chloride melts. The reported data show that it is important to control the corrosion process by clarifying the structure of each melt in order to select a highly compatible system of molten salt and structural material.

Numerical simulation study on microwave joining of Hastelloy C-276 plates using Inconel-718 interface powder

Microwave joining is an emerging technique for the joining of metallic materials because it can join metals faster and offers uniform heating. The current work studies the multi-physics simulation of a microwave-joined Hastelloy C-276 plate with Inconel 718 interface powder inside a multimode microwave applicator at 2.45 GHz and 900 W. The distribution of electric field, temperature, and thermal stress in the joint were analyzed to understand the microwave-joined Hastelloy C-276 plates. The results revealed that the maximum values of electric field strength and temperature at the central plane of symmetry were 7.4 × 104 V/m and 1.43 × 103 ⁰C, respectively. The maximum thermal stress (1.37 × 109N/m2) was estimated using von-Mises criterion. Resistive losses were found to be maximum i.e., 2.72 × 108 W/m3 at the ends of the graphite plate. The study determined the optimum parameters for microwave joining of Hastelloy C-276 plates.

Nano and micron WC particles reinforced Hastelloy C22 coatings manufactured by directed energy deposition

The performance of Hastelloy C22 matrix composite with different reinforced particles is strongly related to microstructural aspect of the coating. In this study, a novel approach for fabricating advanced and high wear resistant nickel-based high-temperature composites by directed energy deposition (DED) was investigated, which enhances the Hastelloy C22 matrix by blending nano and micron WC particles. The microstructure and phase composition of the WC/C22 composite coatings were analyzed by scanning electron microscopy (SEM), transmission electron microscopy (TEM) and X-ray diffraction (XRD). The main phases of WC/C22 composite coating are γ-Ni, M6C, WC, W2C and M12C, where M12C and M6C are distributed at grain boundaries to inhibit grain growth and play the role of fine grain strengthening. In performance testing, the nano/micron WC/C22 composite coating showed a 71.04% increase in microhardness, a 92.3% reduction in mass loss, and significantly improved electrochemical corrosion performance compared to the C22 coating.