Research Progress Regarding Quantitative Characterization and Control Technology of Residual Stress in Superalloy Forgings

doi:10.11900/0412.1961.2023.00246

Acta Metall Sin

2023, Vol. 59

Issue (9): 1144-1158 DOI: 10.11900/0412.1961.2023.00246

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Research Progress Regarding Quantitative Characterization and Control Technology of Residual Stress in Superalloy Forgings

BI Zhongnan¹^,²(

), QIN Hailong¹^,², LIU Pei², SHI Songyi², XIE Jinli¹^,², ZHANG Ji¹^,²

¹Beijing Key Laboratory of Advanced High Temperature Materials, Central Iron and Steel Research Institute, Beijing 100081, China
²Gaona Aero Material Co., Ltd., Beijing 100081, China

Cite this article:

BI Zhongnan, QIN Hailong, LIU Pei, SHI Songyi, XIE Jinli, ZHANG Ji. Research Progress Regarding Quantitative Characterization and Control Technology of Residual Stress in Superalloy Forgings. Acta Metall Sin, 2023, 59(9): 1144-1158.

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Abstract

Residual stress exists in an equilibrium state inside an object without external forces, mainly due to uneven plastic deformation during object preparation. Superalloys exhibit low stacking fault energy and face difficulty in recovery. Therefore, compared with the residual stress in other metal materials, the residual stress in superalloys accumulates easily and is difficult to release and control, causing various problems in their subsequent processing and service. Starting from the formation and evolution mechanism of residual stress in superalloy forgings, this article reviews the research progress regarding the casting, forging, heat treatment, machining, and welding processes involved in residual stress characterization, numerical simulation, optimization control, etc. and focuses on analyzing the interaction behaviors between multiscale residual stress and precipitation phase transformation in superalloys. Further, this article analyzes the impact of residual stress on the service performance of superalloy forgings; the possibility of reasonable preset and utilization of residual stress is envisioned based on this.

Key words: superalloy residual stress formation mechanism numerical simulation optimization and control

Received: 05 June 2023

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	BI Zhongnan
	QIN Hailong
	LIU Pei
	SHI Songyi
	XIE Jinli
	ZHANG Ji

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https://www.ams.org.cn/EN/10.11900/0412.1961.2023.00246 OR https://www.ams.org.cn/EN/Y2023/V59/I9/1144

Fig.1 Residual stress distribution maps of IN718 disc samples^[33]
(a) schematic of testing process (e_a, e_r, and e_h indicate axial, radial, and hoop directions, respectively. positions are in mm)
(b) residual stress maps of water quenched disc samples

Fig.2 Comparisons between experimental measure-ments and finite element (FE) results at different temperatures and strain rates ( $ε ˙$ ) in GH4169 alloy^[49]
(a)

ε ˙

= 10^-2 s^-1 (b)

ε ˙

= 10^-3 s^-1 (c)

ε ˙

= 10^-4 s^-1

Fig.3 Coupled model for residual stress calculation in temperature field, microstructure field, and stress field

Fig.4 Calculation results of residual stress after casting in GH4169 alloy
(a, b) hoop stress (a) and effective stress (b) in ingot (c, d) hoop stress (c) and effective stress (d) after homogenization

Fig.5 Stress relaxation vs time in the center of the disk during the ageing treatment^[62]
(a) heating by ceramic blanket under clad insulation
(b) evolution of residual stress in the center of disk during ageing treatment

Fig.6 Schematic of residual stress control device for superalloys based on precise regulation of cooling field (super gas cooling) (a) and implementation effect (b)

Fig.7 Hoop residual stress distributions of disk forgings measured by contour method
(a) before cooling-field optimizing
(b) after cooling-field optimizing
(c) designing of cooling-field to achieve residual stress preset

Fig.8 Hoop residual stress distributions of GH4169 disk forgings measured by contour method
(a-c) before (a) and after 37000 r/min (b) and 42000 r/min (c) pre-spin of water-quenched samples (d-f) before (d) and after 37000 r/min (e) and 42000 r/min (f) pre-spin of samples with cooling-field optimized

Fig.9 TEM bright-field images with [001] _γ of stress free samples (a, b) and disk samples (c, d) with residual stress aged for 0.5 h (a, c) and 8 h (b, d)^[62]

Fig.10 Effects of γ" phase variant selection behavior on the stress-strain relationship of GH4169 alloy
(a) applied stress-strain curves for quasi-static in situ neutron tensile deformation (TA for tensile-aged, CA for compressive-aged)
(b) evolution of hkl-specific lattice strain of the γ phase along the longitudinal direction^[88]
(c) lattice strain evolution of the γ and γ" phases

Fig.11 Low cycle fatigue test results of GH4169 alloy discs with different residual stresses^[91]
(a) schematic of low cycle fatigue test method (EDM—electrical discharge machining, ω—angular speed)(b) crack length with fatigue cycles
(c) workpieces after low cycle fatigue fracture

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