Indiana University-Purdue University Indianapolis (IUPUI) / Additively manufactured (AM) metals have been increasingly fabricated for structural applications. However, a major hurdle preventing their extensive application is lack of understanding of their mechanical properties. To address this issue, the objective of this research is to develop a computational model to simulate the creep behavior of nickel alloy 718 manufactured using the laser powder bed fusion (L-PBF) additive manufacturing process. A finite element (FE) model with a subroutine is created for simulating the creep mechanism for 3D printed nickel alloy 718 components. A continuum damage mechanics (CDM) approach is employed by implementing a user defined subroutine formulated to accurately capture the creep mechanisms. Using a calibration code, the material constants are determined. The secondary creep and damage constants are derived using the parameter fitting on the experimental data found in literature. The developed FE model is capable to predict the creep deformation, damage evolution, and creep-rupture life. Creep damage and rupture is simulated as defined by the CDM theory. The predicted results from the CDM model compare well with experimental data, which are collected from literature for L-PBF manufactured nickel alloy 718 of creep deformation and creep rupture, at different levels of temperature and stress. Using the multi-regime Liu-Murakami (L-M) and Kachanov-Rabotnov (K-R) isotropic creep damage formulation, creep deformation and rupture tests of both the secondary and tertiary creep behaviors are modeled. A single element FE model is used to validate the model constants. The model shows good agreement with the traditionally wrought manufactured 316 stainless steel and nickel alloy 718 experimental data collected from the literature. Moreover, a full-scale axisymmetric FE model is used to simulate the creep test and the capacity of the model to predict necking, creep damage, and creep-rupture life for L-PBF manufactured nickel alloy 718. The model predictions are then compared to the experimental creep data, with satisfactory agreement. In summary, the model developed in this work can reliably predict the creep behavior for 3D printed metals under uniaxial tensile and high temperature conditions.

The present diploma thesis is focused on the effect of AlCr layer on the low cycle fatigue behaviour of cast polycrystalline superalloy IN713LC at 800°C. Protective layer is made by chemical vapour deposition followed by heat treatment. Fatigue tests were conducted in strain control mode with constant total strain amplitude and strain rate. The fatigue behaviour is assessed by cyclic hardening/softening curves, cyclic stress-strain curves, Manson-Coffin curves and Basquin curves. Microstructure was observed in as-received state and also after cyclic loading by means of optical microscopy and SEM.

No description available.

One of the main sources of energy in this modern world is the gas turbine.  They reach extremely high working temperatures at peak capacity and hence require materials that can withstand the same.  Nickel-based superalloys have been widely used as working materials due to their various high-temperature properties, which help protect them from oxidation, corrosion,  and  creep.  This  high-temperature  strength  is  provided by the  gamma  prime (γ′)  phase  for  most  nickel-based  alloys.  This  study  deals  with understanding  the  effect of the mean γ′ phase size affected by different times and temperatures.  Different trial alloys have undergone different primary ageing cycles, followed by a subsequent secondary ageing  cycle.  Further,  the  mean  gamma  prime size  calculated  using  Image-Pro  coupled with  a  probability  density  function  for the mean  size  showed  significant  γ′  coarsening. Different temperatures and holding times also allowed for significant growth of secondary gamma prime structures.  These structures were found to impact the mean gamma prime size calculations significantly with their influence on the mechanical properties remaining unknown.  However, the mean gamma prime size remains similar to what was desired. / En av de viktigaste energikällorna i denna moderna värld är gasturbinen. De når extremt höga arbetstemperaturer vid toppkapacitet och kräver därför material som klarar av den höga temperaturen. Nickelbaserade superlegeringar har använts i stor utsträckning som material på grund av deras olika högtemperaturegenskaper, som hjälper till att skydda dem från oxidation, korrosion och krypning. Denna högtemperaturs hållfasthet uppnås från gamma prim-fasen (γ′) för de flesta nickelbaserade legeringar. Denna studie handlarom att förstå effekten av den genomsnittliga γ′-fasstorleken som påverkas av olika tider och temperaturer. Olika legeringar har genomgått olika primära åldringscykler, följt av en sekundär åldringscykel. Vidare visade den genomsnittliga gamma-prim storleken som beräknades med Image-Pro tillsammans med en sannolikhets densitetfunktion för medelstorleken av γ′ förgrovning. Olika temperaturer och hålltider möjliggjorde också betydande tillväxt av sekundära gamma-primstrukturer. Dessa strukturer visade sig påverka beräkningarna av den genomsnittliga gamma-primstorleken och egenskaperna av de mekaniska egenskaperna förblir okända. Den genomsnittliga gamma-primstorleken blir liknande det som var önskvärt.

No description available.

Increasing energy demand leads to two crucial problems for the whole society. One is the economic cost and the other is the pollution of the environment, especially CO2 emissions. Despite efforts to adopt renewable energy sources, fossil fuels will continue to dominate. The temperature and stress are planned to be raised to 700 °C and 35 MPa respectively in the advanced ultra-supercritical (AUSC) power plants to improve the operating efficiency. However, the life of the components is limited by the properties of the materials. The aim of this thesis is to investigate the high temperature properties of materials used for future power plants. This thesis contains two parts. The first part is about developing creep rupture models for austenitic stainless steels. Grain boundary sliding (GBS) models have been proposed that can predict experimental results. Creep cavities are assumed to be generated at intersection of subboundaries with subboundary corners or particles on a sliding grain boundary, the so called double ledge model. For the first time a quantitative prediction of cavity nucleation for different types of commercial austenitic stainless steels has been made. For growth of creep cavities a new model for the interaction between the shape change of cavities and creep deformation has been proposed. In this constrained growth model, the affected zone around the cavities has been calculated with the help of FEM simulation. The new growth model can reproduce experimental cavity growth behavior quantitatively for different kinds of austenitic stainless steels. Based on the cavity nucleation models and the new growth models, the brittle creep rupture of austenitic stainless steels has been determined. By combing the brittle creep rupture with the ductile creep rupture models, the creep rupture strength of austenitic stainless steels has been predicted quantitatively. The accuracy of the creep rupture prediction can be improved significantly with combination of the two models. The second part of the thesis is on the fatigue properties of austenitic stainless steels and nickel based superalloys. Firstly, creep, low cycle fatigue (LCF) and creep-fatigue tests have been conducted for a modified HR3C (25Cr20NiNbN) austenitic stainless steel. The modified HR3C shows good LCF properties, but lower creep and creep-fatigue properties which may due to the low ductility of the material. Secondly, LCF properties of a nickel based superalloy Haynes 282 have been studied. Tests have been performed for a large ingot. The LCF properties of the core and rim positions did not show evident differences. Better LCF properties were observed when compared with two other low γ’ volume fraction nickel based superalloys. Metallography study results demonstrated that the failure mode of the material was transgranular. Both the initiation and growth of the fatigue cracks were transgranular. / <p>QC 20160905</p>

A superliga policristalina à base de níquel MAR-M247 foi desenvolvida na década de 70. Sua ótima composição, estabilidade microestrutural, excelente resistência à fluência e à oxidação e boa resistência à corrosão a quente faz dessa superliga uma das mais utilizadas em rotores durante os últimos 20 anos. Os objetivos do presente trabalho são a produção e caracterização microestrutural e mecânica de rotores da superliga MARM247 (10% peso Co, 10W, 8.25Cr, 5.5Al, 3Ta, 1.5Hf, 1Ti, 0.7Mo, 0.15C, 0.05Zr, 0.015B, Ni balanço). Os rotores foram obtidos pela técnica de microfusão por cera perdida na empresa Açotécnica S.A. (Jandira/SP) em diferentes temperaturas de vazamento e isolamento do molde cerâmico. Os materiais foram analisados por microscopia ótica e eletrônica de varredura (MEV/EDS), análise térmica diferencial (DTA), macro/microdureza e ensaios de tração convencional a 25oC e a 760oC. Além disso, os materiais passaram por tratamentos térmicos de solubilização e envelhecimento em diferentes temperaturas e tempos a fim de avaliar as mudanças microestruturais. Com a ajuda do software de cálculo termodinâmico Thermocalc foram feitas simulações das relações de fases utilizando a composição média da superliga MAR-M247. Os resultados permitiram obter uma condição de processamento (temperatura de vazamento e condição de isolamento) com maior quantidade de peças sem defeitos. Além disso, os experimentos permitiram definir uma condição ideal para o tratamento térmico de solubilização da superliga MAR-M247. / The polycrystalline nickel-based superalloy MAR-M247 was developed in the 1970s. Its optimal alloy composition, microstructural stability, excellent resistance to creep and oxidation and good resistance to hot corrosion make the MAR-M247 superalloy one of the alloys widely used in turbine rotors during the last 20 years. The aims of the present work are the production and the microstructural and mechanical characterization of rotors made of MAR-M247 superalloy (10 wt. % Co, 10W, 8.25Cr, 5.5Al, 3Ta, 1.5Hf, 1Ti, 0.7Mo, 0.15C, 0.05Zr, 0.015B, Ni balance). The rotors were produced by using the lost-wax technique at different pouring temperatures and isolation of the shell mold at the Açotécnica S.A. company (Jandira/SP). The materials were analyzed by optical and scanning electron microscopy (SEM/EDS), differential thermal analysis (DTA), macro/microhardness and tensile tests at 25oC and 760oC. Besides, the materials were submitted to solution and ageing treatments at different temperatures and times in order to evaluate de microstructural changes. With the aid of the thermodynamic calculation software Thermocalc, simulations of phase relations were made using the average composition of the MAR-M247 superalloy. The results allowed to obtain a processing condition (pouring temperature and isolation condition) with larger amount of rotors without defects. Moreover, the experiments allowed to define an ideal solution heat treatment condition of MAR-M247 superalloy.

Tato práce obsahuje přehled superslitin na bázi niklu, jejich obrábění za vysokého tlaku chladicí kapaliny, týká se také metod optimalizace pro tento typ obrábění a následné analýzy opotřebení nástroje. Tato studie byla vytvořena ve spolupráci se společností Safran, experimentální část byla zrealizována ve výrobním závodě Evry-Corbeil ve Francii. Experimentální část práce se týká optimalizace řezných podmínek pro vnitřní hrubovací soustružení součástí pro letecký průmysl za vysokého tlaku chladicí kapaliny. Cíle práce byly následující: srovnání rozdílných vyměnitelných břitových destiček dodaných společností Safran, návrh hrubovacích strategií a určení optimálních podmínek pro každou z vybraných strategií. Byly uvažovány dvě rozdílné strategie: soustružení s konstantním posuvem a šířkou záběru ostří a tzv. „ramping“. Pro každou ze strategií byla provedena operace čelního a podélného soustružení. Výsledky byly porovnány na základě ekonomického a produktivního kritéria.

A superliga policristalina à base de níquel MAR-M247 foi desenvolvida na década de 70. Sua ótima composição, estabilidade microestrutural, excelente resistência à fluência e à oxidação e boa resistência à corrosão a quente faz dessa superliga uma das mais utilizadas em rotores durante os últimos 20 anos. Os objetivos do presente trabalho são a produção e caracterização microestrutural e mecânica de rotores da superliga MARM247 (10% peso Co, 10W, 8.25Cr, 5.5Al, 3Ta, 1.5Hf, 1Ti, 0.7Mo, 0.15C, 0.05Zr, 0.015B, Ni balanço). Os rotores foram obtidos pela técnica de microfusão por cera perdida na empresa Açotécnica S.A. (Jandira/SP) em diferentes temperaturas de vazamento e isolamento do molde cerâmico. Os materiais foram analisados por microscopia ótica e eletrônica de varredura (MEV/EDS), análise térmica diferencial (DTA), macro/microdureza e ensaios de tração convencional a 25oC e a 760oC. Além disso, os materiais passaram por tratamentos térmicos de solubilização e envelhecimento em diferentes temperaturas e tempos a fim de avaliar as mudanças microestruturais. Com a ajuda do software de cálculo termodinâmico Thermocalc foram feitas simulações das relações de fases utilizando a composição média da superliga MAR-M247. Os resultados permitiram obter uma condição de processamento (temperatura de vazamento e condição de isolamento) com maior quantidade de peças sem defeitos. Além disso, os experimentos permitiram definir uma condição ideal para o tratamento térmico de solubilização da superliga MAR-M247. / The polycrystalline nickel-based superalloy MAR-M247 was developed in the 1970s. Its optimal alloy composition, microstructural stability, excellent resistance to creep and oxidation and good resistance to hot corrosion make the MAR-M247 superalloy one of the alloys widely used in turbine rotors during the last 20 years. The aims of the present work are the production and the microstructural and mechanical characterization of rotors made of MAR-M247 superalloy (10 wt. % Co, 10W, 8.25Cr, 5.5Al, 3Ta, 1.5Hf, 1Ti, 0.7Mo, 0.15C, 0.05Zr, 0.015B, Ni balance). The rotors were produced by using the lost-wax technique at different pouring temperatures and isolation of the shell mold at the Açotécnica S.A. company (Jandira/SP). The materials were analyzed by optical and scanning electron microscopy (SEM/EDS), differential thermal analysis (DTA), macro/microhardness and tensile tests at 25oC and 760oC. Besides, the materials were submitted to solution and ageing treatments at different temperatures and times in order to evaluate de microstructural changes. With the aid of the thermodynamic calculation software Thermocalc, simulations of phase relations were made using the average composition of the MAR-M247 superalloy. The results allowed to obtain a processing condition (pouring temperature and isolation condition) with larger amount of rotors without defects. Moreover, the experiments allowed to define an ideal solution heat treatment condition of MAR-M247 superalloy.

En service, les matériaux constituant les aubes de turbine aéronautique (superalliages à base nickel) sont soumis à des environnements agressifs susceptibles d’altérer leurs propriétés structurales. Les atmosphères oxydantes impliquées sont en général complexes (O2, H2O, CO2, SO2, NOx…), la quantité d’eau présente pouvant en particulier varier selon le régime moteur et les conditions environnantes (nuages, précipitations, humidité de l’air). Pour apporter une protection contre l’oxydation à haute température, on met en œuvre des revêtements alumino-formeurs sur lesquels une barrière thermique peut, de plus, être déposée. Le présent travail se proposait donc d’étudier l’influence de l’eau, sous forme vapeur et/ou liquide, sur le comportement de revêtements alumino-formeurs de référence, ou développés au LaSIE (barbotine d’aluminium, électrodéposition de CeO2), selon différents régimes d’oxydation (isotherme et cyclique). Afin de se rapprocher des conditions en service, une démarche scientifique originale a été proposée avec la mise en œuvre de conditions de vieillissement et post-vieillissement variées, à haute température, lors des phases de refroidissement, ou encore à température ambiante. Les expériences menées ont montré qu’une introduction de vapeur d’eau n’a que peu d’effet en régime isotherme à 1100°C, notamment lorsqu’une couche d’alumine alpha s’est développée en surface. L’ajout d’eau à froid (humidité relative,gouttes d’eau) accroît l’écaillage des couches d’oxydes, au-delà d’un temps d’oxydation critique, alors que l’apport d’eau lors de la phase de refroidissement des cycles thermiques conduit à une dégradation catastrophique des aluminures de nickel par un mécanisme combinant fatigue thermique et piqûration. / Upon service, aero-turbine blades (nickel-based superalloys) are submitted to high temperature degradation that may alter their structural properties. The oxidizing atmospheres are particularly complex (O2, H2O, CO2, SO2, NOx…) with variable water vapour contents as function of the engine regime and the atmospheric conditions (clouds, rain, relative humidity of air). These substrate materials are protected by alumina-forming coatings to improve their oxidation resistance, while additional thermal barrier coatings insulate the hottest parts. This PhD project aims at studying the effect of water (vapour, liquid) on the degradation of conventional and new coatings (Al slurry, electrodeposited CeO2) developed at the LaSIE laboratory under different oxidation regimes (isothermal and cyclic). An approximation to service conditions was proposed through an original methodology in which several oxidation and post-ageing conditions for different oxidation ranges (hot, upon cooling, at room temperature) were performed. The experiments showed little effect of water vapour mixed with air at 1100°C in isothermal conditions, in particular when the alumina scale grew over the surface. In contrast, water-containing environments at room temperature (relative humidity, water drops) increased the spallation of the oxide scales above a critical threshold time. Cyclic oxidation with water cooling provoked in turn, a catastrophic failure of the aluminide coatings by a mechanism involving thermal fatigue and pitting corrosion.