Please wait a minute...
金属学报  2026, Vol. 62 Issue (3): 497-508    DOI: 10.11900/0412.1961.2024.00064
  研究论文 本期目录 | 过刊浏览 |
GH4169高温合金环轧过程组织模型适配性研究及应用
魏振, 李昕, 江河(), 王川, 董建新
北京科技大学 材料科学与工程学院 北京 100083
Microstructure Models Adaptability and Its Application in Ring Rolling Process of GH4169 Superalloy
WEI Zhen, LI Xin, JIANG He(), WANG Chuan, DONG Jianxin
School of Materials Science and Engineering, University of Science and Technology Beijing, Beijing 100083, China
引用本文:

魏振, 李昕, 江河, 王川, 董建新. GH4169高温合金环轧过程组织模型适配性研究及应用[J]. 金属学报, 2026, 62(3): 497-508.
Zhen WEI, Xin LI, He JIANG, Chuan WANG, Jianxin DONG. Microstructure Models Adaptability and Its Application in Ring Rolling Process of GH4169 Superalloy[J]. Acta Metall Sin, 2026, 62(3): 497-508.

全文: PDF(4318 KB)   HTML
摘要: 

为了探究高温合金环锻件成形过程中复杂的组织演变规律,本工作研究了现有GH4169合金组织模型对环轧过程的适配性,针对环轧过程中再结晶动力学方程对应变速率、温度和时间的高度非线性,对现有组织模型进行了适配性修正。利用FORTRAN语言将修正前后的组织模型分别写入程序并采用Simufact软件调用,之后对环轧过程进行微观组织模拟,建立了可以实现各工艺流程间组织遗传的数值模拟的方法,并通过实验验证了适配性修正后组织演化模型的正确性和该模拟方法的可行性。采用电子背散射衍射(EBSD)技术和建立的数值模拟方法对环锻件典型混晶区域进行了对比分析。结果表明,环锻件截面的再结晶组织由动态再结晶组织和亚动态再结晶组织组成。通过建立的数值模拟方法分析了两道次环轧时道次变形量对环锻件组织的影响。结果表明,增大终轧变形量有利于提高环锻件的组织均匀性。

关键词 高温合金环锻件环轧组织模拟    
Abstract

Superalloy ring forgings are a class of prototypical rotary components extensively used in casings, combustion chambers, sealing rings, and support rings in the aviation, aerospace, and nuclear energy fields. These components are often subjected to severe conditions, such as high temperatures, pressures, and rotational speeds as well as the combined effects of high- and low-frequency vibrations. As a result, these ring forgings exhibit excellent mechanical properties and thermal endurance. The microstructure determines the overall mechanical properties of the ring forgings. Their production is complex and involves multiple cycles of thermal deformation. During the thermal deformation phase, the alloy's microstructure undergoes a series of alterations due to the synergistic effects of thermal and mechanical forces. If recrystallization in the preceding stage is incomplete, the resulting microstructure may become heterogeneous and can be carried over to later stages, potentially leading to the formation of mixed crystals. This phenomenon can considerably affect the mechanical performance of ring forgings. Currently, the preparation and formation of ring forgings in China largely rely on traditional “experience-based optimization” approach, which is time-consuming and costly. Therefore, it is essential to establish an accurate microstructural evolution model and predict microstructural changes during thermal processing using numerical simulations. These improvements will enable better control of the alloy microstructure and the optimization of the manufacturing process. To better understand the complex microstructural evolution during the superalloy ring forging formation process, the adaptability of the existing GH4169 alloy microstructure model to the ring rolling process was investigated. Due to the highly nonlinear relationships between the recrystallization kinetics equations and factors such as the strain rate, temperature, and duration of ring rolling, the existing microstructure model was modified. Both the existing and modified models were programmed in FORTRAN language and implemented in Simufact software to simulate microstructural evolution during ring rolling. A numerical simulation method that captures the microstructure inheritance over multiple processing steps was established. The modified model's accuracy and simulation method's feasibility were verified through experiments. A comparative analysis of typical mixed-crystal regions in ring forgings using EBSD and the established numerical simulation, showed that the recrystallized structure of ring forgings combines dynamic and meta-dynamic recrystallization structures. Finally, the established simulation method was employed to analyze the effect of pass deformation on the microstructure during two-pass ring rolling. The results showed that increasing the final rolling deformation improved the uniformity of the ring forgings' microstructure.

Key wordssuperalloy    ring forging    ring rolling    microstructure simulation
收稿日期: 2024-03-01     
ZTFLH:  TG146.1  
基金资助:国家自然科学基金项目(92160201);无锡市产业前瞻与关键技术研发项目(G20191004)
通讯作者: 江 河,jianghe@ustb.edu.cn,主要从事高温合金研究
Corresponding author: JIANG He, professor, Tel: 13811910685, E-mail: jianghe@ustb.edu.cn
作者简介: 魏 振,男,1999年生,博士生
图1  实验所用GH4169合金原始组织的OM像
ModelFormulasRef.
Critical strain

εc=8.87×10-4 d00.2Z0.099             (ε˙0.01 s-1)

εc=9.57×10-6 d00.196Z0.167          (ε˙<0.01 s-1)

[18]
Dynamic recrystallization

Xd=1-exp-ln2εε0.51.68  (T1010 ), ε0.5=0.037d00.2Z0.058

Xd=1-exp-ln2εε0.51.90  (T>1010 ), ε0.5=0.029d00.2Z0.058

dd=1.301×103Z-0.124

[18]
Meta-dynamic recrystallization

Xmd=1-exp-ln2tt0.51, t0.5=1.7×10-5 d0-5ε-2.0ε˙-0.08exp12000T

dm=8.28 d00.29ε-0.14Z-0.03

[18]
Grain growthdg3-d03=9.8×1019 tgexp-437000RT[18]
Average grain size1dav2=Xddd2+Xmdm2+Xndn2[19]
表1  适配性修正前GH4169合金的组织演化模型[18,19]
ModelFormula
Dynamic recrystallization

ΔXd=-exp-0.693εε0.51.68-1.164ε0.5εε0.50.68Δε      (T1010 )

ΔXd=-exp-0.693εε0.51.90-1.317ε0.5εε0.50.90Δε      (T>1010 )

Xdi=Xdi-1+ΔXdi

Meta-dynamic recrystallization

Xmd=1-exp-0.693teqt0.5ref1

t0.5ref=1.7×10-5d0-5ε-2.0ε˙-0.08exp120001253

teq=iΔtiexp1200011253-1Ti

表2  适配性修正后的GH4169合金再结晶模型
图2  GH4169合金环轧过程有限元模拟组织模型调用流程
图3  环轧有限元模型
图4  模型修正前后环锻件横截面动态再结晶分数对比
图5  模型修正前后环锻件横截面心部再结晶分数变化曲线及分布对比
图6  模型修正前后环锻件各位置平均晶粒尺寸对比
图7  环锻件截面微观组织的OM像
图8  实验测量与计算模拟所得环锻件各点平均晶粒尺寸对比
图9  环轧后环锻件典型区域的局部取向差(KAM)分布图及等效塑性应变分布图
图10  基于修正模型的环轧并空冷后环锻件横截面的再结晶情况
GroupDeformation amount of the 1st pass / %Deformation amount of the 2nd pass / %Total deformation%Average grain size / μmRecrystallization fraction
125154048.120.28
220204033.670.47
315254029.790.60
4404018.131.00
表3  各道次变形量分配及环锻件横截面心部再结晶和平均晶粒尺寸结果
图11  环轧并空冷后环锻件横截面平均晶粒尺寸和再结晶分数分布
[1] Xie D, Wang Y, Ouyang Q Y, et al. Analytical calculation model for radial-axial coordinated feed strategy in large-scale flat ring rolling based on ultimate bending moment [J]. J. Mater. Process. Technol., 2023, 319: 118072
doi: 10.1016/j.jmatprotec.2023.118072
[2] Lin Y C, Qian S S, Chen X M, et al. Staggered spinning of thin-walled Hastelloy C-276 cylindrical parts: Numerical simulation and experimental investigation [J]. Thin-Walled Struct., 2019, 140: 466
doi: 10.1016/j.tws.2019.04.004
[3] Lv N, Liu D, Yang Y H, et al. Studying the residual stress homogenization and relief in aerospace rolling ring of GH4169 alloy using ageing treatment [J]. Int. J. Adv. Manuf. Technol., 2021, 112: 3415
doi: 10.1007/s00170-021-06612-7
[4] Hu Y, Liu D, Yang Y H, et al. Multi-objective optimization of cavity design for GH4738 superalloy profile ring rolling process based on FEM and RSM [J]. Int. J. Adv. Manuf. Technol., 2022, 123: 2929
doi: 10.1007/s00170-022-10364-3
[5] Jiang H, He F Y, Xu L, et al. Research progress on ring rolling technology of superalloy ring forging [J]. Rare Met. Mater. Eng., 2021, 50: 1860
[5] 江 河, 何方有, 许 亮 等. 高温合金环形件环轧工艺研究进展 [J]. 稀有金属材料与工程, 2021, 50: 1860
[6] Chen M C, Zhu C D, Yu Z Q, et al. A novel process for manufacturing large-diameter thin-walled metal ring: Double-roll pendulum hot rotary forging technology [J]. J. Manuf. Process., 2022, 76: 379
doi: 10.1016/j.jmapro.2022.02.020
[7] Xiao G F, Xia Q X, Zhang Y L, et al. Manufacturing of Ni-based superalloy thin-walled components by complex strain-path spinning combined with solution heat treatment [J]. Int. J. Adv. Manuf. Technol., 2021, 117: 199
doi: 10.1007/s00170-021-07676-1
[8] Chen M S, Wang G Q, Li H B, et al. Annealing treatment methods and mechanisms for refining mixed and coarse grains in a solution treatment nickel-based superalloy [J]. Adv. Eng. Mater., 2019, 21: 9
[9] Chen M S, Zou Z H, Lin Y C, et al. Microstructural evolution and grain refinement mechanisms of a Ni-based superalloy during a two-stage annealing treatment [J]. Mater. Charact., 2019, 151: 445
doi: 10.1016/j.matchar.2019.03.037
[10] Yuan S J, Fan X B. Developments and perspectives on the precision forming processes for ultra-large size integrated components [J]. Int. J. Extrem. Manuf., 2019, 1: 022002
[11] Qi H P, Li Y T. Research status and developing trends on the ring rolling process of profile ring parts [A]. International Conference on the Technology of Plasticity [C]. Cambridge: Elsevier, 2017: 1260
[12] Zhang B Y, Wang Z T, Yu H, et al. Microstructural origin and control mechanism of the mixed grain structure in Ni-based superalloys [J]. J. Alloys Compd., 2022, 900: 163515
doi: 10.1016/j.jallcom.2021.163515
[13] Hu Y, Liu D, Zhu X L, et al. Effect of rolling passes on thermal parameters and microstructure evolution via ring-rolling process of GH4738 superalloy [J]. Int. J. Adv. Manuf. Technol., 2018, 96: 1165
doi: 10.1007/s00170-017-1549-6
[14] Sun Z C, Yang H, Ou X Z. Effects of process parameters on microstructural evolution during hot ring rolling of AISI 5140 steel [J]. Comput. Mater. Sci., 2010, 49: 134
doi: 10.1016/j.commatsci.2010.04.036
[15] Zhu X L, Liu D, Xing L J, et al. Microstructure evolution of inconel 718 alloy during ring rolling process [J]. Int. J. Precis. Eng. Manuf., 2016, 17: 775
doi: 10.1007/s12541-016-0095-8
[16] Li L H, Dong J X, Zhang M C, et al. Integrated simulation of the forging process for GH4738 alloy turbine disk and its application [J]. Acta Metall. Sin., 2014, 50: 821
doi: 10.3724/SP.J.1037.2013.00675
[16] 李林翰, 董建新, 张麦仓 等. GH4738合金涡轮盘锻造过程的集成式模拟及应用 [J]. 金属学报, 2014, 50: 821
doi: 10.3724/SP.J.1037.2013.00675
[17] Li X J, Cui Z S, Feng C, et al. Multi-scale simulation on the whole integrated forming process for nuclear pressure vessel head and over cone [J]. J. Plast. Eng., 2016, 23: 1
[17] 李馨家, 崔振山, 冯 超 等. 核电封头-过渡锥体一体化成形全工艺过程多尺度模拟 [J]. 塑性工程学报, 2016, 23: 1
[18] Na Y S, Yeom J T, Park N K, et al. Simulation of microstructures for alloy 718 blade forging using 3D FEM simulator [J]. J. Mater. Process. Technol., 2003, 141: 337
doi: 10.1016/S0924-0136(03)00285-1
[19] Yeom J T, Lee C S, Kim J H, et al. Finite-element analysis of microstructure evolution in the cogging of an alloy 718 ingot [J]. Mater. Sci. Eng., 2007, A449-451: 722
[20] Cui Z S, Liu C. Numerical prediction and experimental research of microstructure development during hot rolling [J]. J. Mech. Eng. 2000, 36(7): 92
[20] 崔振山, 刘 才. 热轧过程微观组织演变的数值预报与试验研究 [J]. 机械工程学报, 2000, 36(7): 92
[21] Yao Z H. Microstructure evolution model and its application during hot deformation for GH864 superalloy [D]. Beijing: University of Science and Technology Beijing, 2011
[21] 姚志浩. GH864合金热变形过程组织演化模型及其应用 [D]. 北京: 北京科技大学, 2011
[22] Jiang S C, Zhang J, He Y H, et al. Microstructure evolution and processing maps of GH4169 during deformation [J]. Iron Steel Vanadium Titanium, 2021, 42(2): 161
[22] 蒋世川, 张 健, 何云华 等. GH4169合金高温变形显微组织演变及热加工图 [J]. 钢铁钒钛, 2021, 42(2): 161
[23] Liu X Z. Research on high temperature ring rolling forming process of ring workpiece of GH4738 alloy [D]. Harbin: Harbin Institute of Technology, 2017
[23] 刘信祖. GH4738合金环形件高温环轧成形工艺研究 [D]. 哈尔滨: 哈尔滨工业大学, 2017
[24] Tang X F, Wang B Y, Zhang H, et al. Study on the microstructure evolution during radial-axial ring rolling of IN718 using a unified internal state variable material model [J]. Int. J. Mech. Sci., 2017, 128-129: 235
doi: 10.1016/j.ijmecsci.2017.04.023
[25] Li Y L, Zeng M T, Tan Y B, et al. Microstructure evolution of Inconel 718 superalloy with fine-grains at different strain during hot deformation [J]. Chin. J. Rare Met., 2023, 47: 807
[25] 李应隆, 曾梦婷, 谭元标 等. 应变量对细晶Inconel 718高温合金热变形组织演变的影响 [J]. 稀有金属, 2023, 47: 807
[26] Nicolaÿ A, Franchet J M, Cormier J, et al. Discrimination of dynamically and post-dynamically recrystallized grains based on EBSD data: Application to Inconel 718 [J]. J. Microsc., 2019, 273: 135
doi: 10.1111/jmi.2019.273.issue-2
[27] Nicolaÿ A, Fiorucci G, Franchet J M, et al. Influence of strain rate on subsolvus dynamic and post-dynamic recrystallization kinetics of Inconel 718 [J]. Acta Mater., 2019, 174: 406
doi: 10.1016/j.actamat.2019.05.061
[28] Lin Y C, Wu X Y, Chen X M, et al. EBSD study of a hot deformed nickel-based superalloy [J]. J. Alloys Compd., 2015, 640: 101
doi: 10.1016/j.jallcom.2015.04.008
[29] Chen X M, Lin Y C, Chen M S, et al. Microstructural evolution of a nickel-based superalloy during hot deformation [J]. Mater. Des., 2015, 77: 41
doi: 10.1016/j.matdes.2015.04.004
[1] 崔天亮, 谢兴飞, 温晓灿, 吕少敏, 曲敬龙, 杜金辉. GH4151难变形高温合金的拉伸行为及其断裂失效机制[J]. 金属学报, 2026, 62(3): 445-457.
[2] 贾玉亮, 张勇佳, 史泽楷, 沈旭, 殷亚军, 施长坤, 周建新, 吕志刚. 高温合金定向凝固雀斑形成机理及控制技术研究进展[J]. 金属学报, 2026, 62(2): 309-327.
[3] 赵晓, 徐超, 江河, 姚志浩, 董建新. GH4738镍基高温合金O累积程度对疲劳性能与晶界损伤的影响及表征[J]. 金属学报, 2026, 62(2): 328-338.
[4] 郭世佳, 李健乐, 袁圣云, 李志刚, 于连旭, 张勇. 一种含稀土新型第四代镍基单晶高温合金的高温氧化行为和 γ' 相稳定性[J]. 金属学报, 2026, 62(2): 351-362.
[5] 闫静, 张佳丽, 邓睿, 何洋, 文新理, 章清泉, 乔利杰. Sc在镍基变形高温合金BYG36真空感应熔炼中的烧损机制[J]. 金属学报, 2026, 62(2): 363-371.
[6] 王洪瑛, 姚志浩, 李大禹, 郭婧, 姚凯俊, 董建新. γ' 相含量粉末及变形高温合金组织和力学性能的异同性[J]. 金属学报, 2025, 61(9): 1364-1374.
[7] 谢信亮, 周丽萍, 余建波, 玄伟东, 陈超越, 王江, 任忠鸣. 横向弱磁场对镍基高温合金发散双晶竞争生长行为的影响[J]. 金属学报, 2025, 61(8): 1203-1216.
[8] 何家宝, 王亮, 张朝威, 邹明科, 孟杰, 王新广, 姜肃猛, 周亦胄, 孙晓峰. Al2O3 涂层对硅基陶瓷型芯与镍基单晶高温合金界面反应的影响[J]. 金属学报, 2025, 61(7): 1093-1108.
[9] 王飞翔, 陈忠奉, 尹晓宇, 熊良华, 谢红兰, 邓彪, 肖体乔. 基于X射线体视成像实现高温合金熔体凝固三维显微结构的原位观测[J]. 金属学报, 2025, 61(7): 1109-1118.
[10] 李永梅, 谭子昊, 王新广, 陶稀鹏, 杨彦红, 刘纪德, 刘金来, 李金国, 周亦胄, 孙晓峰. 一种低成本第三代单晶高温合金的高温氧化行为[J]. 金属学报, 2025, 61(7): 1049-1059.
[11] 李大禹, 姚志浩, 赵杰, 董建新, 郭婧, 赵宇. FGH4720Li粉末高温合金在近服役条件下的组织与力学性能演变规律[J]. 金属学报, 2025, 61(6): 826-836.
[12] 李新宇, 白佳铭, 张浩鹏, 李晓鲲, 贾建, 刘常升, 刘建涛, 张义文. 先进镍基粉末高温合金FGH4108在不同应力条件下的蠕变行为[J]. 金属学报, 2025, 61(5): 757-769.
[13] 周一鸣, 韩勇军, 谢光, 郑伟, 肖炎彬, 潘阳, 张健. 一种镍基高温合金的高温HCl腐蚀行为[J]. 金属学报, 2025, 61(5): 770-782.
[14] 张浩鹏, 白佳铭, 李新宇, 李晓鲲, 贾建, 刘建涛, 张义文. HfTa对镍基粉末高温合金蠕变断裂特征和性能的影响[J]. 金属学报, 2025, 61(4): 583-596.
[15] 周生玉, 胡明昊, 李冲, 丁海民, 郭乾应, 刘永长. 一种 γ'/γ'' 相强化镍基高温合金的蠕变行为[J]. 金属学报, 2025, 61(2): 226-234.