Research Progress on Surface Impact Strengthening Mechanisms and Application of Nickel-Based Superalloys

doi:10.11900/0412.1961.2023.00134

Acta Metall Sin

2023, Vol. 59

Issue (9): 1173-1189 DOI: 10.11900/0412.1961.2023.00134

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Research Progress on Surface Impact Strengthening Mechanisms and Application of Nickel-Based Superalloys

WANG Lei¹(

), LIU Mengya¹, LIU Yang¹(

), SONG Xiu¹, MENG Fanqiang²

¹Key Laboratory for Anisotropy and Texture of Materials, Ministry of Education, Northeastern University, Shenyang 110819, China
²Sino-French Institute of Nuclear Engineering and Technology, Sun Yat-Sen University, Zhuhai 519000, China

Cite this article:

WANG Lei, LIU Mengya, LIU Yang, SONG Xiu, MENG Fanqiang. Research Progress on Surface Impact Strengthening Mechanisms and Application of Nickel-Based Superalloys. Acta Metall Sin, 2023, 59(9): 1173-1189.

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Abstract

There has been rapid development in the turbine power systems of aeroengines and gas turbines. Consequently, the application of surface impact strengthening technology for the surface strengthening of superalloys used in turbine rotors and its corresponding mechanisms have attracted wide attention. However, it is difficult to prevent the recovery and recrystallization of the surface hardened layer of superalloys serviced at high temperatures. This leads to the degradation of both the surface strengthening/toughening and fatigue resistance. This is the main hurdle restricting the wide application of surface impact strengthening technology for key components of advanced superalloys. In this paper, the progress made in surface impact strengthening mechanisms and the applications of nickel-based superalloys in recent years are summarized. The effect of surface impact strengthening on the surface strength, toughness, and fatigue resistance of nickel-based superalloys is analyzed. The evolution of the microstructure of the hardened surface of the alloys during long-term aging at high temperatures, and its effect on high-temperature stability are explored. The paper aims to provide essential and important information for developing surface impact strengthening mechanisms of nickel-based superalloys and improving the fatigue resistance of turbine rotors of aeroengines and gas turbines.

Key words: nickel-based superalloy surface strengthening technology anti-fatigue manufacturing hardened layer high temperature stability of microstructure and property

Received: 29 March 2023

ZTFLH:

TG132.2

Fund: National Key Research and Development Program of China(2022YFB3705102);National Key Research and Development Program of China(2022YFB3705101);National Science and Technology Major Project of China(J2019-VI-0020-0136);National Natural Science Foundation of China(U1708253);National Natural Science Foundation of China(51571052)

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	WANG Lei
	LIU Mengya
	LIU Yang
	SONG Xiu
	MENG Fanqiang

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https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00134 OR https://www.ams.org.cn/EN/Y2023/V59/I9/1173

Fig.1 Effects of shot peening on the residual compress-ive stress distribution of surface hardened layer of FGH96 alloy^[30]
(a) before shot peening (turning)
(b) ceramic bead peening and compound shot peening (SP1—parallel to the tool mark, SP2—perpendicular to the tool mark)

Fig.2 Nanocrystalline and deformation twins layer with gradient distribution in the cross-sectional surface hardened layer obtained by shot peening of GH4169 alloy^[33]

Fig.3 Surface morphologies of GH4169 alloy before (a) and after shot peening with intensities of 0.15 mmA (b) and 0.3 mmA (c)^[13]

Fig.4 Effects of shot peening on fatigue crack initiation location of Udimet 720Li alloy before (a, c) and after (b, d) shot peening under the same load amplitude^[35] (Fig.4c enlarged for red frame in Fig.4a, Fig.4d enlarged for the lake blue frame in Fig.4b)

Fig.5 Effects of surface shot peening with different intensities on S-N curves of GH4169 superalloy^[13] (S—stress amplitude, N—number of cycle to failure)

Fig.6 Residual compressive stress distributions of hard-ened layer of IN718 alloys with different hole extrusion treatments^[43] (Inset shows the stress and distance direction of hole extrusion treatment)

Fig.7 Surface morphologies of FGH96 alloys with different surface treatments^[48]
(a) mechanical polishing
(b) laser shocking processing (LSP)

Fig.8 Morphologies of γ″ phase and dislocation patterns in the hardened layers of IN718 alloy treated with LSP (a) and warm laser shocking processing (WLSP) (Blue arrows show the γ″ phase/high-density dislocation complex structure containing stacking faults and nanosized twins) (b)^[52]

Fig.9 Residual compressive stress distributions of GH4586 alloy treated with LSP of single laser pulse^[50]
(a) surface layer along the diameter direction
(b) depth direction from the surface to the inside

Fig.10 Effect of LSP on grain size and number of twins on the surface of GH4586 alloy^[50]
(a) untreated (b) LSP

Fig.11 Effect of LSP on the dislocation density of matrix and microstructure of γ′ phase in the surface hardened layer in nickel-based single crystal superalloy^[65]
(a) untreated
(b-d) low (b) and high (c) magnified images of samples treated by LSP, and SAED pattern of Fig.11c (d)

Fig.12 Effect of LSP and WLSP on the surface microhardness distribution of IN718 alloy^[19]

Fig.13 Morphologies of complex structure of γ″ phase/high-density dislocation and micro-twins in γ″ phase induced by strong impact in the surface hardened layer of WLSP-treated IN718 superalloy^[19]
(a) morphology of complex structure of γ″ phase/high-density dislocation
(b) dark field morphology of γ″ phase in Fig.13a (Blue arrows show micro-twins)
(c) micro-twins in γ″ phase induced by strong impact (Blue arrows show micro-twins)
(d) HRTEM image of micro-twins at the γ/γ″ interface

Fig.14 HRTEM images of the details of γ″/γ interface in the surface hardened layer of WLSP-treated IN718 superalloy^[52] (a, d) HRTEM images of γ″/γ interface (a) and γ″ phase (d) in the surface hardened layer (Insets show fast Fourier transform (FFT) diffraction patterns) (b, e) magnified parts in the red boxes in Fig.14a (b) and Fig.14d (e), showing HRTEM images and corresponding maps of the geometric phase images (GPA) strain component ε_xx (ε_xx —x-direction in-plane strain) (c, f) line profiles of strain maps scanned along lines 1, 2, and 3 in Fig.14b (c) and lines 4, 5, and 6 in Fig.14e (f)

Fig.15 Effects of aging on the microhardness distribution in the surface hardened layer of LSP and WLSP samples of IN718 alloy at 650^oC for 200 h^[52] (Insets show optical micrographs of the Vickers indentation. LTA—long-term aging)

Fig.16 Comparisons of residual stress distribution of the surface hardened layer of IN100 alloy after aging at 650^oC for 100 h^[82]
(a) shot peening (b) LSP

Fig.17 Micro-hardness distributions and depth changes of the surface hardened layer of LSP and WLSP IN718 alloys after aging at high temperatures (NA—non-aging)^[81]
(a) micro-hardness of surface hardened layer after aging at different temperatures treated by LSP and WLSP
(b) comparison of micro-hardness of hardened layer
(c) comparison of hardened layer depth

Fig.18 Effects of long-term aging on the contribution increment of strengthening mechanism of the surface hardened layer of LSP and WLSP IN718 alloys^[81] (Δσ_D—strength contribution from dislocation strengthening, Δσ_GB—strength contribution from grain boundary strengthening)

Fig.19 Geometrically necessary dislocation (GND) density (ρ_GND) maps (a, b, d, e) and corresponding normal distribution statistical diagrams of GND density (c, f) of the surface hardened layer of LSP (a-c) and WLSP (d-f) IN718 alloys before (a, d) and after (b, e) long-term aging at 650^oC^[52] (RD—rolling direction, TD—transverse direction, ND—normal direction)

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