Research Progress in Powder Metallurgy Superalloys and Manufacturing Technologies for Aero-Engine Application

doi:10.11900/0412.1961.2019.00119

Acta Metall Sin

2019, Vol. 55

Issue (9): 1133-1144 DOI: 10.11900/0412.1961.2019.00119

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Research Progress in Powder Metallurgy Superalloys and Manufacturing Technologies for Aero-Engine Application

ZHANG Guoqing^1,⁴,ZHANG Yiwen^2,³,ZHENG Liang^1,⁴(

),PENG Zichao¹

1. Advanced High Temperature Structural Materials Laboratory, Beijing Institute of Aeronautical Materials, Beijing 100095, China
2. High Temperature Material Research Institute, Central Iron and Steel Research Institute, Beijing 100081, China
3. Beijing Key Laboratory of New Superalloy Materials, Central Iron and Steel Research Institute, Beijing 100081, China
4. AECC Additive Manufacturing Technology Innovation Center, Beijing 100095, China

Cite this article:

ZHANG Guoqing,ZHANG Yiwen,ZHENG Liang,PENG Zichao. Research Progress in Powder Metallurgy Superalloys and Manufacturing Technologies for Aero-Engine Application. Acta Metall Sin, 2019, 55(9): 1133-1144.

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Abstract

The research progress in powder metallurgy (PM) superalloys and manufacturing technologies are reviewed. The key control factors of Ar gas atomization (AA) powder manufacturing are introduced, including the aspects of the equipment development, atomization process, particle size, oxygen content, powder morphology and inclusion control. For the turbine disk manufacturing technology, the research progress of dual-property turbine disk, dual-alloy integral turbine wheel technologies and isothermal forging die materials are summarized. In the field of basic research, high-throughput experiment, advanced characterization and creep behavior of PM superalloys were introduced. According to the current major demand for aero-engines and 3D printing, the future of PM superalloys manufacturing technology is prospected.

Key words: aero-engine powder metallurgy superalloy Ar gas atomized powder manufacturing turbine disk manufacturing technology 3D printing powder high-throughput experiment

Received: 17 April 2019

ZTFLH:

TG132.32，TG113

Fund: Supported by National Key Research and Development Program of China(2017YFB0305800,2016YFB0701404);National Natural Science Foundation of China(51434007);Ministry of Industry and Information Technology of China /Horizon 2020 China-European Union Aeronautical Science & Technology Cooperation Program(MJ-2015-H-G-104);UK Diamond Light Source(EE10597)

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	Guoqing ZHANG
	Yiwen ZHANG
	Liang ZHENG
	Zichao PENG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00119 OR https://www.ams.org.cn/EN/Y2019/V55/I9/1133

Fig.1 Development of powder metallurgy (PM) superalloys

Table 1 Chemical compositions of typical powder metallurgy superalloys^[5,15,16] (mass fraction / %)

Table 2 Main chemical compositions of FGH4103, FGH4104 and FGH4097 PM superalloys (mass fraction / %)

Fig.2 Microstructures of FGH4103 (a), FGH4104 (b) and FGH4097 (c) PM superalloys

Table 3 Tensile properties of of FGH4103, FGH4104 and FGH4097 PM superalloys

Table 4 Stress rupture and low cycle fatigue (LCF) strengths of FGH4103, FGH4104 and FGH4097 PM superalloys

Fig.3 Schematic of vacuum induction melting gas atomization (VIGA) powder manufacturing furnace

Fig.4 Gas-only flow field velocity magnitude profile and curve in axis

Fig.5 Simulation of liquid disintegration process(a) primary disintegration (b) secondary disintegration

Fig.6 Particle trajectory of powder with different particle diameters

Fig.7 Schematic of particle image velocimetry (PIV) experiment (a) and contour of velocity vector (b)

Fig.8 Droplet size with different atomized pressures (water atomization physical simulation)

Fig.9 Relationship between gas content and superalloy powder particle size

Fig.10 Morphology of Ar gas atomized superalloy powders

Fig.11 Macrostructure of dual-alloy auxiliary power unit (APU) turbine wheel

Fig.12 Calculated and experimentally measured creep test behavior at 700 ℃ for FGH96 alloy

Fig.13 High throughput experiment of microstructure evolution from powder to bulk superalloy (a)^[52] and fast characterization of minor phase change by synchrotron X-ray diffraction (b) (T_centre——centre temperature, T_γ'——γ' solvus temperature, T_IM——incipient melting temperature, T_L——liquidus temperature)

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