Superalloy Inconel Research Articles

Quantitative Characterization and Mapping Relationship between Microstructure, Composition, Orientation, and Mechanical Properties of Nickel-Based Superalloy Inconel 718

Abstract This study explores the relationship between the microstructure, composition, orientation, and mechanical properties of the nickel-based superalloy Inconel 718. Employing scanning electron microscopy (SEM), electron microprobe (EMP), nano-indentation, and other techniques, the study observes the structure, confirms the composition, determines orientation, and tests mechanical properties in specific micro-zones. Findings reveal a uniform grain distribution in Inconel 718, with a minor δ-phase presence at grain boundaries. There is a notable enrichment of Nb at the grain boundaries, whereas Fe and Cr levels are lower at these boundaries compared to the grain interiors. The indentation hardness and modulus at the grain boundaries are markedly higher than those within the grains. Moreover, grains with different orientations exhibit diverse microscale mechanical properties, such as hardness and elastic modulus. This research establishes a quantitative mapping relationship between the microstructure, composition, orientation, and mechanical properties of Inconel 718, providing a foundation for future multiscale (micro to macro) mechanical property investigations.

Fabrication and tribological properties of WC-reinforced Inconel X-750 alloy at elevated temperature

The nickel-based superalloy Inconel X-750, valued for its exceptional mechanical properties, is used in gas-lubricated foil bearings. However, prolonged exposure to high temperatures can lead to wear failure, affecting their service life. Here, we propose a novel method named ultrasonic strengthening grinding (USG) that applies a WC coating on Inconel X-750. Friction tests reveal that at 600 °C, the friction coefficient and wear rate of the USG-treated samples were reduced by 30.2 % and 79.7 %, respectively. Detailed experiments and analysis demonstrate that the surface grain refinement and the WC-rich coating cooperate to improve the high-temperature tribological properties. These findings offer new insights into the design of wear-resistant coatings for enhancing the high-temperature tribological performance of Inconel X-750 Alloy.

Pulsed Unipolar-Polarisation Plasma Electrolytic Polishing of Ni-Based Superalloys: A Proof of Conception

The enhanced performance of aerospace equipment drives parts development towards integration, complexity, and structural optimization. This advancement promotes metal near-net fabrication technologies like wire electrical discharge machining (WEDM) and 3D printing. However, the high initial surface roughness from WEDM or 3D printing poses significant challenges for the high-performance surface finishing required. To effectively reduce the surface roughness of the workpieces with high initial surface roughness, this paper proposes pulsed unipolar-polarisation plasma electrolytic polishing (PUP-PEP). The study examined the material removal mechanisms and surface polishing quality of PUP-PEP. This technique combines the high current density and material removal rate of the electrolytic polishing mode with the superior surface polishing quality of PEP through voltage waveform modulation. For an Inconel-718 superalloy part fabricated by WEDM, PUP-PEP reduced surface roughness from Ra 7.39 μm to Ra 0.27 μm in 6 min under optimal conditions. The roughness decreased from Ra 7.39 μm to Ra 0.78 μm in the first 3 min under pulsed unipolar-polarisation voltage, resulting in a remarkable 233% increase in efficiency compared to that with conventional PEP. Subsequently, the voltage output voltage is transformed into a constant voltage mode, and PEP is continued based on PUP-PEP to finally reduce the workpiece surface roughness value to Ra 0.27 μm. The proposed PUP-PEP technology marks the implementation of ‘polishing’ instead of conventional rough-finish machining processes, presenting a new approach to the surface post-processing of metal near-net fabrication technologies.

A Study on Microstructure Evolution and Mechanical Properties of Inconel 690 Subjected to Milling Process

The metallic materials subjected to machining‐induced severe plastic deformation can experience alterations of microstructures and mechanical properties, affecting the functional performances of the components. This study concentrates on the microstructure evolution and mechanical properties analysis of Ni‐based superalloy Inconel 690 under severe plastic deformation induced by milling process. The obtained results show that the microstructures of the machined surface and subsurface exhibit the characteristic of gradient distribution. Plastic behaviors involving dislocation multiplication, grain deformation and refinement, increment of local misorientation and average intragranular misorientation, and transition from high‐angle grain boundaries to low‐angle grain boundaries occur in the superficial layer of the machined workpiece. Both the intensity and the affected depth of plastic deformation for the superficial layer are strengthened following the cutting speed and feed increase, which is attributed to higher cutting forces. No white layer and phase transformation is found under all cutting conditions. In addition, the nanohardness of the superficial layer shows the reduction tendency of hardening effect from the surface to the bulk of the machined workpiece material. With the increase in cutting speed and feed, the affected zones of residual stresses and work hardening below the machined surface become wider.

Thermal Analysis of Micro-Channel Internal Cooling in Cutting Tools: A Machine Learning Approach

The use of coolants for cutting process in metal cutting operations is customary. Turning causes high cutting heat in nickel base super alloy Inconel 718. Nonetheless, it should be acknowledged that although flooding techniques are commonly used in the machining of super alloys, these flood cooling methods have extremely poor efficiencies. Another alternative to increase the cooling capabilities of fluids would be an internal-cooling approach that would enable to lower machining temperatures significantly. The heat dissipation ability in the tool is also greatly influenced by the micro-channel diameter of tool which further causes a significant effect on the coolant outlet velocity. A design of an internal-cooling single point cutting tool with micro channel structures for enhanced coolant heat transfer capability and reduced machining temperature is used for turning Inconel 718 under dry, flooded cooling and internal cooling to study the effects of cooling conditions on cutting force, cutting temperature and surface quality. A regression model is built using the Random Forest (RF) and Support Vector Regression (SVR) methods in machine learning framework. These models were then used to forecast input parameters, such as channel diameter and inlet pressure, which made it easier to obtain output data, such as pressure and maximum velocities at different notches. Eighty percent of the data in the dataset is used to train the model and with the remaining twenty percent set aside for evaluating the model's functionality. When comparing internal-cooling technology to traditional flood cooling, there are clear benefits including increased heat transfer efficiency, which leads to lower cutting temperatures, less cutting force, and better surface quality. More specifically, in the internal-cooling configuration, a direct relationship is shown between rising coolant inlet pressure and falling cutting force and temperature over time. Further highlighting the advantages of this cooling strategy is the relationship between increased intake pressure and decreased surface roughness.

Influence of alloying elements on stacking fault energy in Ni and Ni-based alloy: A first–principles study

The study of the reliability of Ni-based alloys and their performance under high-temperature radiation environments is crucial for nuclear reactor application. The first-principles study has been utilized to investigate the effect of individual alloying elements (Cr, Fe, Mo, Nb) on the stacking fault energy (SFE) of pure Ni in order to understand their specific contribution in the superalloy Inconel 718 (IN718). The result shows that the addition of an alloying element in pure Ni reduces the SFE value with the most significant reduction seen in IN718 alloy. The role of individual alloying element in the reduction of the SFE in IN718 is conjectured. The DOS at EF of all the elemental substitution configurations were also calculated and significant change is seen in the alloy IN718. Such reduction is due to the interrupted distribution of d-electrons and atomic bonding on the stacking fault planes, reflected in the SFE value.

Nitriding Treatments in Nickel–Chromium-Based Superalloy INCONEL 718: A Review

This literature review focuses on the nitriding treatments of nickel-based superalloy UNS N07718, also called INCONEL 718. This alloy was selected due to the relevance of this alloy in the aerospace and oil and gas industries. The referenced studies reflect a clear trend towards improving superalloys through advanced nitriding processes, highlighting plasma nitriding as one of the most promising techniques to enhance alloy 718 against corrosion and wear. The importance of optimizing nitriding parameters, such as temperature and time, is emphasized to increase wear and corrosion resistance while minimizing adverse effects like delamination or the formation of undesirable phases. Finally, the most appropriate alternatives for future research are recommended.

High Temperature Intergranular Oxidation of Nickel Based Superalloy Inconel 718

AbstractIntergranular oxidation (IGO) of the Ni-based superalloy Inconel 718 was studied at 650 °C, 700 °C and 900 °C. The oxidized samples were characterized by X-ray diffraction and scanning electron microscopy. For all the studied temperatures, the external scale was mainly composed of Cr2O3, while the oxides along the grain boundaries were rich in Al and, to a minor extent, Ti. This was consistent with thermodynamic computations. The time evolution of the maximum depth of IGO was found to be parabolic with an apparent activation energy of 164 kJ/mol. The results of this study confirm with three temperatures that IGO kinetics can be described using an extension of the Wagner’s theory of internal oxidation, as recently suggested in the literature at 850 °C. According to this description, the mechanisms controlling the IGO kinetics of Inconel 718 are the aluminum diffusion in the alloy matrix and the oxygen diffusion along the interface between the alloy matrix and the oxidized grain boundary.

Impact of morphological and mechanical components on inconel 625 grinding using common cylindrical grinding wheels

This study used a grinding technique based on Gas Tungsten Arc Welding (GTAW) to create walls composed of Inconel 625 alloy. Mechanical and microstructural (MM) adjustments are structural and mechanical alterations that take place during the additive manufacturing process of Inconel 625 grinding. A thorough examination of the modifications made to the nickel superalloy Inconel 625's (I-625) microstructure was conducted during the grinding process. A circular weave and a stringer bead design were used to construct the wall. Tensile properties and microstructural analyses were assessed for each wall. Using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS), the fracture zones of the tensile specimens were examined. The microstructure is mostly composed of equiaxed dendrites, although a unique combination of discontinuous and continuous cellular dendrites can be observed along the cross-section. In tensile testing, circular woven walls performed better than stringer bead walls. The EDS and AFM results show that Ni and Cr make up the majority of the fracture zone, with traces of Nb and Mo. Because there are no lave phases, the fracture mode is ductile. The elemental mapping, which shows the homogenous dispersion of Ni and Cr inside the fracture zone, provides additional evidence in favor of the ductile failure mode. The UTS of the time-consuming TS samples is somewhat higher and exhibits a steadily rising bias in comparison to the specimens with quick TS. The highest level of the UTS sample is 10 %.

Effects of Heat Input and Intertrack Overlap on the Microstructure and Properties of Inconel 686 Weld Overlays.

The objective of this study was to investigate how weld overlays with nickel superalloys are important for the integrity, due the high temperatures and corrosive environments that can be experienced in mineral processing environments, of mining and processing equipment. The Ni-Cr-Mo superalloy Inconel 686 overlays are fabricated through automatic gas metal arc welding with variations in arc voltage and travel speed (i.e., heat input), and they have overlap between adjacent weld tracks for applications in the mining and minerals sector. The impact of variations in the process parameters and the size of the weld overlapping on the dilution, solidification morphology, microsegregation, and microhardness were investigated. Both geometric and chemical composition definitions were used to quantify the extent of the weld dilution. Subsequently, the weld geometry and dilution were correlated with the solidification microstructure and phase transformations. The maximum dilutions were measured to be 13.63% (1/2 overlap, 5.96 kJ·cm-1) and 15.39% (1/3 overlap, 4.77 kJ·cm-1), which shows that less of an overlap increases the dilution level. Scanning electron microscopy and chemical composition analysis revealed that an increase in weld heat input and dilution level led to higher levels of microsegregation for Mo and Cr, as well as the volume fraction of Mo- and Cr-rich phases in the interdendritic/intercellular regions in the overlay layer. Analysis of the weld overlays in the current study revealed strong and unprecedented connections between the weld overlay process conditions, the resultant metallurgy (i.e., dendrite arm spacing, microsegregation, and phase formation), and the hardness of the overlay. It was concluded that the optimal weld overlays in the processing window studied in this investigation were fabricated at mid-level heat inputs (i.e., 4-5 kJ·cm-1) and a 1/2 track overlap.

Experimental study on the preparation of superalloy Inconel718 heat exchanger channels by electrochemical etching method

The nuclear energy field requires the construction of heat exchangers that can withstand sufficiently high temperatures. In this paper, the etching technique was utilized to fabricate heat exchange channels on Inconel718 plates, and experiments were carried out in NaCl-ethylene glycol solution, three temperature conditions of 35 °C, 40 °C, and 45 °C, and two concentrations of electrolyte solutions, 0.5 mol/L and 1 mol/L, with the addition of 50 kHz ultrasound for comparison. The experimental results show that the etching rate can be as high as 2.894 mm/h, and the inter-electrode current is as high as 908 mA. The roughness characterization of the etching channel Ra and Rq measured by the aspheric surface measuring instrument can be as low as 2.416 μm and 2.647 μm, respectively. In the images generated by SEM scanning, it is found that uneven distribution of pits and bumps exist in the etching channel, but their diameters are all less than 0.1 μm, which means the etched channel is acceptably smooth.

X-Ray Diffraction Measurements for Inconel 718 Alloy Elements Created by Incremental Methods

Abstract The work presented is the result of the implementation of diffraction measurements: phase composition and stresses resulting from additive manufacturing process of nickel superalloy Inconel 718 components print. With the help of diffraction methodologies, the key parameters from the point of view of the quality of prints and their strength were determined. The existence of individual phases in the material after printing was demonstrated, and the surface variation of the stress values was presented, showing its dependence on the geometry of the printed part – measurements were made at various points on the surface of samples with different geometries. In addition, the variation of the stress level was shown depending on the distance of the measurement point from the build platform on which the additive manufacturing process was carried out. Components were printed on the surface of a single build plate in order to study the effect of printing differently oriented samples with respect to the platform geometry, as well as the mutual effect of the temperature of samples printed first on the stress state of elements printed in subsequent steps of the procedure, and the effect of the temperature of elements printed later on the rate of temperature decrease, and consequently on the stress state, of elements printed first.

Optimization of superalloy Inconel 718 micro-milling process by combined Taguchi and multi-criteria decision making method

Optimization of superalloy Inconel 718 micro-milling process by combined Taguchi and multi-criteria decision making method

Grain size sensitive modelling of the nonlinear behaviour and fatigue damage of Inconel 718 superalloy

Fatigue tests conducted on various types of materials often exhibit significant scatter, particularly in High Cycle Fatigue tests, attributed to imperfections located at the scale of the microstructure. In metallic materials, one contributor to this dispersion, but not the only one, is the variation in grain size, which cannot be uniform in a structure that has undergone a complex thermal history during its manufacturing process. This paper introduces a new model for predicting the evolution of the grain size in the nickel-based superalloy Inconel® 718 based on the applied thermal load and explores its impact on cyclic elasto-viscoplastic behaviour and fatigue life predictions. The proposed approach is applied to a complete numerical life analysis of an aircraft turbine disk.

A comparative tribological study on as-cast and heat-treated Inconel-718 superalloy at elevated temperature

The application of Inconel-718 ranges from structural components to engine parts such as turbine blades and compressor discs. Inconel-718 is an age-hardenable alloy. We are presenting a comparative tribological study on as-cast and heat-treated Inconel-718 superalloy. The wear behavior of both as-cast and aged Inconel-718 alloy was investigated using a linear reciprocating tribometer at [Formula: see text]C, [Formula: see text]C, and [Formula: see text]C against Si[Formula: see text]N[Formula: see text] ball. The heat treatment of Inconel-718 alloy resulted in the improvement of the hardness of the alloy. All the tribological tests were conducted under a constant 20 N normal load. The observed coefficient of friction was found to be decreasing with the increase in temperature. The wear tracks were characterized by a three-dimensional optical profilometer and scanning electron microscopy (SEM). The observed wear volume loss (mm[Formula: see text]) of the aged alloy was less than that of the as-cast Inconel-718 alloy. SEM of the worn sample reveals that the main operating wear mechanism at [Formula: see text]C is delamination whereas at elevated temperatures of [Formula: see text]C and [Formula: see text]C, the main operating wear mechanism is abrasion, adhesion, oxidation and spalling. SEM of the counter-surface was also conducted in order to understand the adhesion on its surface and it was found that the adhered oxide contained mainly Ni and Nb oxides.

Dissolution studies during the mechanical alloying of Inconel-718 superalloy based elemental powders

Inconel-718 superalloy with a nominal composition of Ni-19.47Fe-18Cr-0.5Al-1Ti-5 Nb-3Mo-0.02Co-0.003B was synthesized by mechanical alloying of elemental powders. Mechanical alloying was carried out in a high energy Simoloyer attritor ball mill. A sufficient quantity of powder was removed at milling intervals of 0, 2, 4, 6, 8, 10, 12, 14, 16, 18, 20, and 22 h for characterization by XRD, SEM, and TEM. The dissolution time of different alloying elements have been discussed in view of their atomic scattering factors and Hume-Rothery principle with the help of XRD and TEM (SAED) analysis. Complete dissolution of Fe took place at 6 h of milling, Nb at 10 h, Cr at 18 h while Mo took 22 h. A complete single-phase solid solution of γ(FCC) matrix was obtained at 22 h of milling. Crystallite size was found to decrease while the lattice parameter increased with milling time. Lattice-strain and dislocation density increased initially and later decreased due to the dynamic recrystallization process taking place within the powder particles during milling. SEM analysis indicated flattening of powder particles during the initial (0 h–4 h) stages of milling followed by heavy cold-welding at the intermediate stages (6 h–12 h). In the final stages of milling (18 h–22 h), an equilibrium between cold welding and fracturing was reached.

Modeling of laser-assisted micro-milling Inconel718

Nickel-based superalloy Inconel718 is a typical difficult-to-machine material with the characteristic of high strength and hardness. Demands for micro parts of nickel-based superalloy Inconel718 are growing in aerospace, biomedical and other fields. Laser-assisted micro-milling (LAMM) can realize precision machining of the workpiece because of its lower cutting force. However, the machining mechanism and the change law of cutting force during LAMM of nickel-based superalloy Inconel718 are still unclear. There is a crucial need for modeling of LAMM Inconel718. This paper explores LAMM of nickel-based superalloy Inconel718 and realizes the simulation of LAMM process. A three-dimensional transient heat transfer finite element (FE) model is established to predict the temperature distribution of a Gaussian heat source in LAMM. Multiple sets of simulations of laser pre-heating with various laser power are conducted to analyze the temperature fields of workpiece and determine the appropriate laser parameters. A novel 3D model of the full machining process of LAMM Inconel 718 is constructed by ABAQUS with multi-subroutine, a fully coupled thermal-mechanical process is achieved. A modified Johnson-Cook constitutive model is used to reflect the size effect and flow stress of LAMM Inconel 718. Finally, the validity of the models is verified by experiments. Based on the verified model, the appropriate laser pre-heating parameters are obtained, and the prediction of cutting forces of LAMM Inconel718 is achieved.

Boiling of Coolant Near the Cutting Edge in High Speed Machining of Difficult-to-Cut Materials

This study investigates film boiling of coolant as a cooling inhibitor in a narrow wedge-shaped space between the tool flank face and the machined surface of a workpiece, observed during high-speed turning of stainless steel SUS304 and nickel-based superalloy Inconel 718. The boiling, likely triggered by high surface temperatures at both the face and surface close to the cutting edge, impedes coolant access to the tool tip area and efficient cooling. Therefore, the impact of coolant pressure on the boiling zone size was initially explored across pressures ranging from 0.1 to 20 MPa. A burn mark band due to coolant boiling, distinctly visible on the flank face of an insert with a yellow hard coating, expanded over cutting time. The film boiling area width, or the distance from the flank wear area to the band, decreased with increasing coolant pressure, reflecting the enhanced cooling ability and tool life with high-pressure coolant. Applying Boyle–Charles’ law to film boiling indicated that vapor pressure was directly related to coolant velocity rather than pressure. In contrast, the boiling area width increased with increasing cutting speed.

Hot Corrosion Behavior of Plasma-Sprayed Gd2Zr2O7/YSZ Functionally Graded Thermal Barrier Coatings

The development of advanced thermal barrier coating (TBC) materials with better hot corrosion resistance, phase stability, and residual stresses is an emerging research area in the aerospace industry. In the present study, four kinds of TBCs, namely, single-layer yttria-stabilized zirconia (YSZ), single-layer gadolinium zirconate (GZ), bilayer gadolinium zirconate/yttria-stabilized zirconia (YSZ/GZ), and a multilayer functionally graded coating (FGC) of YSZ and GZ, were deposited on NiCrAlY bond-coated nickel-based superalloy (Inconel 718) substrates using the atmospheric plasma spray technique. The hot corrosion behavior of the coatings was tested by applying a mixture of Na2SO4 and V2O5 onto the surface of TBC, followed by isothermal heat treatment at 1273 K for 50 h. The characterization of the corroded samples was performed by X-ray diffraction (XRD), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) to identify physical and chemical changes in the coatings. GIXRD was used to analyze the residual stresses of the coatings. Residual stress in the FGC coating was found to be −15.2 ± 10.6 MPa. The wear resistance of TBCs is studied using a linear reciprocating tribometer, and the results indicate that gadolinium zirconate-based TBCs showed better performance when deposited in bilayer and multilayered functionally graded TBC systems. The wear rate of as-coated FGC coatings was determined to be 2.90 × 10−4 mm3/Nm, which is lower than the conventional YSZ coating.

Research on microplastic deformation of Inconel718 under the conditions of high temperature and high strain rate

The compression experiments of the nickel-based superalloy Inconel718 were carried out with the help of split Hopkinson pressure bar device, and the microstructure evolution law in the compression deformation of the alloy was studied by means of optical microscopy, electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM). Based on the dislocation theory, a three-dimensional discrete dislocation dynamics model is established. By simulating the dynamic evolution of the discrete dislocation, the interaction of the dislocation itself and the formation of the dislocation microstructure were captured, and further explore the microplastic deformation process of Inconel718. The results show that deformation conditions significantly affect the rheological behavior and dynamic recrystallization behaviour. The cross slip of dislocations is closely related to temperature and strain rate, which in turn affect the dislocation configuration. The deformation mechanism of Inconel718 under the conditions of high temperature and high strain rate is jointly dominated by dislocation slip and twin deformation. As the temperature increases, the average Schmidt factor increases, and more dislocation slip systems are activated. As the strain rate increases, the number of deformation twins increases, while the thickness of deformation twins decreases.