Ce travail est consacré à l'étude de l'ingénierie des joints de grains dans les superalliages à base de Nickel pour disques de turbines aéronautiques. L'ingénierie des joints de grains a montré son efficacité dans l'amélioration des propriétés en fatigue et en fluage dans certains alliages de cuivre et de nickel. Cette amélioration est obtenue en réalisant une succession de déformations à température ambiante séparées par des traitement thermiques. Ce traitement a pour objectif de modifier la distribution du réseau de joints de grains. L'objectif de l'étude est d'adapter ces traitements au procédé du forgeage à haute température des superalliages. Une étude expérimentale est menée pour mettre en évidence l'influence des paramètres de forgeage sur les caractéristiques du réseau de joints de grains. La caractérisation de ce réseau est faite grâce à la réalisation de cartographies d'orientations cristallographiques par EBSD. Une méthode de caractérisation innovante basée sur la discrétisation des cartographies en réseaux de points triples est proposée. Cette méthode permet d'analyser la connectivité du réseau de joints de grains en vue d'une corrélation avec les propriétés mécaniques. / This work is dedicated to the study of Grain Boundary Engineering in Ni-based superalloys for aircraft turbine disk. The grain boundary engineering has proven its efficiency for the improvement of the fatigue and creep properties of copper and nickel alloys. This improvement is achieved by performing a succession of room temperature deformations interspaced by heat treatments to modify the distribution of the grain boundary network. The aim of the study is to adapt these processes to high temperature forging of superalloys. An experimental study is achieved to highlight the influence of forging parameters on the grain boundary network. The characterization of the grain boundary network is made through the completion of crystallographic orientation mapping by EBSD. An innovative characterization method based on the discretization of orientation maps in a triple junction network is proposed. This method allows to analyze the connectivity in the grain boundary network with the objective of a correlation with mechanical properties.

Turbine components operate under severe loading conditions and at high and varying temperatures that result in thermal stresses in the presence of temperature gradients created by hot gases and cooling air. Moreover, static and cyclic loads as well as the motion of rotating components create mechanical stresses. The combined effect of complex thermo-mechanical stresses promote nucleation and propagation of cracks that give rise to fatigue and creep failure of the turbine components. Therefore, the relationship between thermo-mechanical stresses, chemical composition, heat treatment, resulting microstructure, operating temperature, material damage, and potential failure modes, i.e. fatigue and/or creep, needs to be well understood and studied. Artificial neural networks are promising candidate tools for such studies. They are fast, flexible, efficient, and accurate tools to model highly non-linear multi-dimensional relationships and reduce the need for experimental work and time-consuming regression analysis. Therefore, separate neural network models for γ’ precipitate strengthened Ni based superalloys have been developed for predicting the γ’ precipitate size, thermal expansion coefficient, fatigue life, and hysteresis energy. The accumulated fatigue damage is then estimated as the product of hysteresis energy and fatigue life. The models for γ’ precipitate size, thermal expansion coefficient, and hysteresis energy converge very well and match experimental data accurately. The fatigue life proved to be the most challenging aspect to predict, and fracture mechanics proved to potentially be a necessary supplement to neural networks. The model for fatigue life converges well, but relatively large errors are observed partly due to the generally large statistical variations inherent to fatigue life. The deformation mechanism map for 1.23Cr-1.2Mo-0.26V rotor steel has been constructed using dislocation glide, grain boundary sliding, and power law creep rate equations. The constructed map is verified with experimental data points and neural network results. Although the existing set of experimental data points for neural network modeling is limited, there is an excellent match with boundaries constructed using rate equations which validates the deformation mechanism map.

Superligas à base de níquel vêm sendo extensivamente utilizadas em diversas aplicações nas indústrias devido ao excelente comportamento mecânico e anticorrosivo. No entanto, essas ligas possuem certas particularidades que levam à necessidade de desenvolvimento de técnicas de inspeção e caracterização metalúrgica, como forma de garantir a integridade estrutural dos componentes fabricados com essas ligas. Neste trabalho, a técnica de correntes parasitas foi aplicada à superligas à base de níquel com duas propostas distintas: 1) Em um primeiro momento foi realizado o estudo da evolução microestrutural da liga Inconel 718 durante o processo de envelhecimento através da combinação do ensaio por correntes parasitas, análise de difração de raios-X, análise metalográfica, medidas de dureza e tamanho de grão. As medidas foram realizadas em amostras submetidas a diferentes ciclos de tratamentos térmicos variando entre 620-1035°C. Os resultados mostraram que as diferentes microestruturas do Inconel 718 têm efeitos distintos na condutividade elétrica quando medidos através da técnica de correntes parasitas. A influência da microestrutura na condutividade pode ser mostrada sendo devido à competição de dois efeitos sobre o espalhamento de elétrons: a purificação da matriz e a morfologia, distribuição e tamanho dos precipitados. A combinação dos valores de dureza e condutividade elétrica provou ser uma forma rápida e prática de determinar o nível de envelhecimento da liga; 2) Em um segundo momento foi desenvolvido um processo de otimização de sensores através de modelagem por elementos finitos (MEF). Através de uma metodologia de otimização, os parâmetros de construção e operação de um sensor foram otimizados para inspeção de defeitos superficiais e subsuperficiais esperados em materiais cladeados com Inconel 625. O sensor com a geometria ótima foi construído e testado a fim de verificar a eficiência do processo de otimização. Uma ótima correlação entre os resultados numéricos e experimentais foi encontrada e o sensor ótimo se mostrou eficiente na inspeção de pequenos defeitos superficiais e subsuperficiais na liga Inconel 625 quando operado nas frequências apropriadas. / Nickel-based superalloys have been extensively used in various industries due to its unique mechanical and corrosion behavior. However, these alloys show particular characteristics which lead to the need for specific inspection and metallurgical characterization techniques in order to ensure the structural integrity of components manufactured from these alloys. In this work , the eddy current technique was applied to nickel-base superalloys with two aims: 1 ) Firstly, the microstructural evolution of Inconel 718 during aging processes has been studied through a combination of eddy current testing, X-ray diffraction analysis, metallography, hardness and grain size measurements. Measurements were carried out in samples subjected to different heat treatment cycles between 620-1035°C. Results show that different microstructures of Inconel 718 have a distinguishable effect on electrical conductivity when this is measured through an appropriately sensitive technique (i.e. eddy current testing). The influence of microstructure on conductivity could be shown to be due to the competition between two effects on the scattering of electrons: matrix purification and precipitate size, distribution and morphology. A combination of hardness values and electrical properties proved to be a fast and practical way of determining the stage of aging of the alloy; 2) An optimization method of eddy current sensor design was developed through finite element modeling (FEM). Through a methodology of optimization, the construction and operation parameters of the sensor were optimized for inspection of superficial and subsuperficial defect, commonly found in weld overlay Inconel 625 claddings. A prototype of this sensor with the optimum geometry was built and tested on blocks identical to those considered in the models in order to verify the efficiency of the optimization process. A very good agreement between numerical and experimental results was found. Moreover, the optimal sensor was efficient to detect small surface and subsurface defects in Inconel 625 when operated at appropriate frequencies.

As superligas a base de níquel apresentam limitações para uso em temperaturas acima de 600 °C. Por este motivo, os revestimentos protetivos podem ser usados como barreiras para evitar a propagação de nucleação e fissuras. O presente trabalho tem por objetivo avaliar as propriedades mecânicas em altas temperaturas de amostras nitretadas por plasma da superliga INCONEL 625 foram realizados ensaios de tração e fluência em amostras com e sem tratamento. Nos ensaios de tração, nas temperaturas de 200 a 700 °C, o material apresentou uma oscilação nos valores de tensão a partir do início da deformação plástica. Este comportamento da curva tensão-deformação serrilhada pode estar associado com a difusão de um soluto intersticial ou pela difusão de átomos substitucionais ou pelo envelhecimento da deformação dinâmica (DSA). Em 600 °C, o aumento da taxa de deformação promoveu um aumento da amplitude e da frequência de oscilação da tensão. Sob níveis de tensões intermediários ou elevados o mecanismo de fluência dominante da liga Inconel 625 foi por escorregamento de discordâncias mostrando-se semelhante ao de muitos metais puros e ligas de soluções sólidas. / Nickel-based superalloys have limitations for use at temperatures above 600 °C. For this reason, protective coatings can be used as barriers to avoid both nucleation and crack propagation. Thus, to evaluate the mechanical properties at high temperatures of plasma nitrided samples of the INCONEL 625 superalloy, tensile and creep tests were performed on samples with and without treatment. In the tensile tests at temperatures of 200 to 700 °C the material showed an oscillation in the tension values from the beginning of the plastic deformation. This behavior of the serrated strain-strain curve may be associated with the diffusion of an interstitial solute or by the diffusion of substitutional atoms or by dynamic strain aging effect. At 600 °C, the increase in strain rate promoted an increase of the amplitude and oscillation frequency of the stress. Under levels of intermediate of elevated stresses, the dominant creep mechanism of the Inconel 625 alloy was like that of many pure metals and alloys of solid solutions which is by slippage of dislocations.

<p>Ni-based superalloys have been widely used for high temperature applications such as turbine blades for jet propulsion and power plants due to their excellent creep, fatigue, and corrosion resistance. But as the demand for higher temperature capability and strength increases, there remains a need to better understand high temperature deformation mechanisms and improve and strengthen superalloys at these elevated temperatures. Recently, a correlation has been observed between solute segregation at planar defects (stacking faults, antiphase boundaries, etc) and enhanced high temperature creep properties – known colloquially as phase transformation strengthening. Experimentally, regardless of alloy composition, strong Co segregation at planar defects along with Cr has been observed. In addition, it has been suggested by density functional theory work that Co would promote Cr concentration at stacking faults by forming strong Cr-Co bonds. Based on these findings, it was hypothesized the presence of Co provides a significant thermodynamic driving force for segregation to planar defects. </p><p>In order to further investigate the correlation between solute segregation and deformation mechanisms the fabrication of a planar front single crystal Ni-based superalloy and its microstructure, alloy composition, and microhardness properties of the as-zone melted and solution heat treated states were investigated and compared to the directionally-solidified state to study the effect of microsegregation on these alloy characteristics. Next, new Co-containing, Cr-free alloys are designed to optimize g-g’ volume fraction, size, and morphology to mimic microstructures observed in single crystal superalloys. The general alloy design strategy and approach are outlined, and the composition, microstructure, phase transformation temperatures, and mechanical properties of new Cr-free and Co-containing alloys are reported. A new set of Cr-free alloys have thus been designed, with modifications of Nb, Ta, and Ti additions ranging from 3 to 7 at.% to investigate the role of these elements on the phase transformation strengthening mechanism at elevated temperatures.</p><p></p>

Ni-based superalloys are the important materials for gas turbines in advancedaeroplane engines . The addition of refractory elements to these superalloys,such as rhenium and tungsten, can significantly improve the hightemperatureperformance by so-called solid-solution hardening. Although thestrengthening effect of refractory elements in Ni-based superalloys have beenknown for a long time, the effective interactions among alloying componentsas well as the atomic ordering in the alloy systems are still under investigationand even under debate. In this work, we study these interactions and thisordering for two binary alloys, Ni-rich Ni-Re and Ni-rich Ni-W, by means ofab initio simulations and statistical mechanics simulations based on the IsingHamiltonian. For the Ni-rich Ni-Re alloys, we show that the effective cluster interactionsvary substantially depending on the temperature, concentration of the componentsand the magnetic state of the matrix. The strain-induced interactionshave large contribution to the nearest-neighbor pair-interactions and some multisitecluster-interactions in the ferromagnetic and nonmagnetic states. Theordering tendency of binary Ni-Re alloy systems can be predicted in terms ofordering energy and enthalpy of formation. We show that the D1a orderedstructure should be stable at the concentration of 20 at.% Re in the Ni-rich Ni–Re alloy system. The Monte Carlo simulations of Ni-Re random alloysshow the existence with the D1a-Ni4Re ordered structure at low temperatures. We also calculated lattice parameters for different compositions of Ni-rich Ni-W alloys, and we find that lattice parameters of random Ni-W alloys increaselinearly with the concentration of W. This is in good agreement withthe Vegard’s law predictions and experimental data. We investigated phasestability of Ni-rich Ni-W alloys in terms of the enthalpies of formation andordering energies. We find the chemical pair interactions are sensitive to themagnetic state and concentration. The calculated strain-induced interactionsare quite large for the first coordination shell, which is due to a large sizemismatch of Ni and W. Taking local lattice relaxation into account, the Ni-Wsystems were modeled by Monte Carlo method. The D1a-Ni4W ordered structurecan be observed up to 22 at.% W. In higher concentrations of W, in ourMC calculations, the DO22-Ni3W and Pt2Mo-Ni2W ordered structures can beobserved in Ni-25 at.% W alloy and Ni-33 at.% W alloy, respectively. / <p>QC 20160721</p>

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<blockquote><div><div>Methods and techniques for tailoring the surface morphology of metallic surfaces are determined in part by the complex behavior of elemental interactions in conjunction with electrochemical reactions. In this work, we show how the surface morphology can be predicted based on experimental data resulting from polarization curves and compositional differences of Fe- and Ni-based superalloys. Electrochemical treatments utilizing NaCl as the electrolyte were adapted using parameters such as the pitting resistance equivalent (PRE) number and polarization curves to obtain both rough and smooth surfaces. Utilizing these metrics, we electrochemically etched Inconel 600, SS304, Inconel 718 and Inconel 625 obtaining average surface roughness values that ranged from 0.05 to 57.4 μm indicating the success of tailoring the technique to obtaining rough and smooth surfaces. The effect of current density, current pulsing, and temperature were varied to elucidate roughness and pitting behavior, and strong correlations to the PRE number and polarization curve properties of the alloy were observed. Heat treatments and subsequent evolution to the microstructure in the form of grain growth and precipitation altered the etching behavior. These techniques can be used in preventing corrosion failure and enhancing electrochemical machining</div></div></blockquote>

No description available.

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