Tailoring the Properties of a Ni-Based Superalloy via Modification of the Forging Process: an ICME Approach to Fatigue Performance

Detrois, Martin; Rotella, John; Hardy, Mark; Tin, Sammy; Sangid, Michael D.

doi:10.1007/s40192-017-0103-6

Title: Tailoring the Properties of a Ni-Based Superalloy via Modification of the Forging Process: an ICME Approach to Fatigue Performance

Journal Article · Wed Nov 01 00:00:00 EDT 2017 · Integrating Materials and Manufacturing Innovation

DOI:https://doi.org/10.1007/s40192-017-0103-6· OSTI ID:1765264

Detrois, Martin ^[1]; Rotella, John ^[2]; Hardy, Mark ^[3]; Tin, Sammy ^[4];

^[2]

Oak Ridge Inst. for Science and Education (ORISE), Oak Ridge, TN (United States); National Energy Technology Lab. (NETL), Albany, OR (United States)
Purdue Univ., West Lafayette, IN (United States)
Rolls-Royce plc, Derby (United Kingdom)
Illinois Inst. of Technology, Chicago, IL (United States)

Traditionally, material design and property modifications are usually associated with compositional changes. Yet, subtle changes in the manufacturing process parameters can also have a dramatic effect on the resulting material properties. In this work, an integrated computational materials engineering (ICME) framework is adopted to tailor the fatigue performance of a Ni-based superalloy, RR1000. An existing fatigue model is used to identify microstructural features that promote enhanced fatigue life, namely a uniform, fine grain size distribution, random orientation, a distinct grain boundary distribution (specifically high twin boundary density and limited low-angle grain boundaries). A deformation mechanism map and process models for grain boundary engineering of RR1000 are used to identify the optimal thermo-mechanical processing parameters to realize these desirable microstructural features. For validation, small-scale forgings of RR1000 were produced and heat-treated to attain fine grain and coarse grain microstructures that represent the conventionally processed and grain boundary engineered (GBE) conditions, respectively. For each of the four microstructural variants of RR1000, the twin density and grain size were characterized and were in agreement with the desired microstructural attributes. In order to validate the deformation mechanisms and fatigue behavior of the material, high-resolution digital image correlation was performed to generate strain maps relative to the microstructural features. The high density of twin boundaries was confirmed to inhibit the length of slip bands, which is directly attributed to extended fatigue life. Thus, this study demonstrated the successful role of models, both process and performance, in the design and manufacture of Ni-based superalloy disk forgings.

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Research Organization:: National Energy Technology Laboratory (NETL), Pittsburgh, PA, Morgantown, WV, and Albany, OR (United States)

Sponsoring Organization:: USDOE Office of Fossil Energy (FE); National Science Foundation (NSF); Rolls-Royce Corporation

Grant/Contract Number:: CMMI 13-34664; 13-34998

OSTI ID:: 1765264

Alternate ID(s):: OSTI ID: 1784734

Report Number(s):: NA

Journal Information:: Integrating Materials and Manufacturing Innovation, Vol. 6, Issue 4; ISSN 2193-9764

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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