Microstructure Models Adaptability and Its Application in Ring Rolling Process of GH4169 Superalloy

doi:10.11900/0412.1961.2024.00064

Acta Metall Sin

2026, Vol. 62

Issue (3): 497-508 DOI: 10.11900/0412.1961.2024.00064

Research paper

Current Issue | Archive | Adv Search

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

Cite this article:

WEI Zhen, LI Xin, JIANG He, WANG Chuan, DONG Jianxin. Microstructure Models Adaptability and Its Application in Ring Rolling Process of GH4169 Superalloy. Acta Metall Sin, 2026, 62(3): 497-508.

Download:

HTML

PDF(4318KB)
Export: BibTeX | EndNote (RIS)

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 words: superalloy ring forging ring rolling microstructure simulation

Received: 01 March 2024

ZTFLH:

TG146.1

Fund: National Natural Science Foundation of China(92160201);Wuxi Industry Foreseeing and Key Technology Research and Development Projects(G20191004)

Corresponding Authors: JIANG He, professor, Tel: 13811910685, E-mail: jianghe@ustb.edu.cn

	Service

	E-mail this article
	Add to citation manager
	E-mail Alert
	RSS
	（）
	Articles by authors
	WEI Zhen
	LI Xin
	JIANG He
	WANG Chuan
	DONG Jianxin

URL:

https://www.ams.org.cn/EN/10.11900/0412.1961.2024.00064 OR https://www.ams.org.cn/EN/Y2026/V62/I3/497

Fig.1 OM image of the GH4169 alloy used in the experiment

Model	Formulas	Ref.
Critical strain	$ε c = 8.87 × 10 - 4 d 0 0.2 Z 0.099 (ε ˙ ≥ 0.01 s - 1)$ $ε c = 9.57 × 10 - 6 d 0 0.196 Z 0.167 (ε ˙ < 0.01 s - 1)$	[18]

Dynamic recrystallization	$X d = 1 - e x p - l n 2 ε ε 0.5 1.68 (T ≤ 1010 ℃), ε 0.5 = 0.037 d 0 0.2 Z 0.058$ $X d = 1 - e x p - l n 2 ε ε 0.5 1.90 (T > 1010 ℃), ε 0.5 = 0.029 d 0 0.2 Z 0.058$ $d d = 1.301 × 103 Z - 0.124$	[18]

Meta-dynamic recrystallization	$X m d = 1 - e x p - l n 2 t t 0.5 1, t 0.5 = 1.7 × 10 - 5 d 0 - 5 ε - 2.0 ε ˙ - 0.08 e x p 12000 T$ $d m = 8.28 d 0 0.29 ε - 0.14 Z - 0.03$	[18]

Grain growth	$d g 3 - d 03 = 9.8 × 1019 t g e x p - 437000 R T$	[18]
Average grain size	$1 d a v 2 = X d d d 2 + X m d m 2 + X n d n 2$	[19]

Table 1 Models for the microstructure evolution of GH4169 superalloy before modification^[18,19]

Model	Formula
Dynamic recrystallization	$Δ X d = - e x p - 0.693 ε ε 0.5 1.68 - 1.164 ε 0.5 ε ε 0.5 0.68 Δ ε (T ≤ 1010 ℃)$ $Δ X d = - e x p - 0.693 ε ε 0.5 1.90 - 1.317 ε 0.5 ε ε 0.5 0.90 Δ ε (T > 1010 ℃)$ $X d i = X d i - 1 + Δ X d i$

Meta-dynamic recrystallization	$X m d = 1 - e x p - 0.693 t e q t 0.5 r e f 1$ $t 0.5 r e f = 1.7 × 10 - 5 d 0 - 5 ε - 2.0 ε ˙ - 0.08 e x p 120001253$ $t e q = ∑ i Δ t i e x p 12000 11253 - 1 T i$

Table 2 Recrystallization models of GH4169 superalloy after modification

Fig.2 Procedure for invoking the microstructure model in finite element simulation of the ring rolling process for GH4169 superalloy (X_r—recrystallization fraction)

Fig.3 Finite element model of ring rolling

Fig.4 Comparisons of the dynamic recrystallization fraction of the ring forging before (a) and after (b) modification of model

Fig.5 Comparisons of the recrystallization fraction curves (a, b) and distributions (c, d) of center of ring forging cross section (P point) before (a, c) and after (b, d) modification of model

Fig.6 Comparisons of average grain size of positions 1-9 in the ring forgings before (a) and after (b) modification of model

Fig.7 Cross-sectional OM images of different positions in Fig.6 (d_BM—average grain size based on un-modified model, d_AM—average grain size based on modified model, d_EXP—experimental average grain size)
(a) position 1 (b) position 2 (c) position 3
(d) position 4 (e) position 5 (f) position 6
(g) position 7 (h) position 8 (i) position 9

Fig.8 Comparison between experimental and simulated values of average grain size of different positions in Fig.6

Fig.9 Kernel average misorientation (KAM) distribution maps of typical locations 1 (a), 5 (b), and 8 (c) and effective plastic strain distribution map (d) of ring forging

Fig.10 Recrystallization conditions of the ring forging after ring rolling and air cooling based on modified model
(a) recrystallization fraction
(b) dynamic recrystallization fraction
(c) meta-dynamic recrystallization fraction

Table 3 Deformation amount in each pass and recrystallization fraction and average grain size at the center of cross section in ring forging

Fig.11 Distributions of average grain sizes (a, c, e, g) and recrystallization fractions (b, d, f, h) air of ring forging after ring rolling and air cooling based on modified model
(a, b) group 1 (c, d) group 2 (e, f) group 3 (g, h) group 4

[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
	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
	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
	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
	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
	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
	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
	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
	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]	CUI Tianliang, XIE Xingfei, WEN Xiaocan, LYU Shaomin, QU Jinglong, DU Jinhui. Tensile Behavior and Fracture Mechanism of Hard-to-Deform GH4151 Superalloy[J]. 金属学报, 2026, 62(3): 445-457.
[2]	JIA Yuliang, ZHANG Yongjia, SHI Zekai, SHEN Xu, YIN Yajun, SHI Changkun, ZHOU Jianxin, LYU Zhigang. Review of the Formation Mechanism and Control Technology for Freckle Defects in Directionally Solidified Superalloys[J]. 金属学报, 2026, 62(2): 309-327.
[3]	ZHAO Xiao, XU Chao, JIANG He, YAO Zhihao, DONG Jianxin. Effect and Characterization of O Accumulation Degree on Fatigue Properties and Grain Boundary Damage in GH4738 Ni-Based Superalloy[J]. 金属学报, 2026, 62(2): 328-338.
[4]	GUO Shijia, LI Jianyue, YUAN Shengyun, LI Zhigang, YU Lianxu, ZHANG Yong. High-Temperature Oxidation Behaviors and γ' Phase Stability of a New Fourth-Generation Single Crystal Superalloy with Rare Earth[J]. 金属学报, 2026, 62(2): 351-362.
[5]	YAN Jing, ZHANG Jiali, DENG Rui, HE Yang, WEN Xinli, ZHANG Qingquan, QIAO Lijie. Burning Loss Mechanism of Sc During Vacuum Induction Melting of Nickel-Based Superalloys[J]. 金属学报, 2026, 62(2): 363-371.
[6]	WANG Hongying, YAO Zhihao, LI Dayu, GUO Jing, YAO Kaijun, DONG Jianxin. Similarities and Differences of Microstructure and Mechanical Properties Between High γ' Content Powder and Wrought Superalloys[J]. 金属学报, 2025, 61(9): 1364-1374.
[7]	ZHANG Tianhao, JU Quan, MENG Zhaobin, WANG Hao, HU Benfu. Microstructural Stability in Tungsten Argon-Arc Welded Joint of GH3230 Superalloy Plate[J]. 金属学报, 2025, 61(9): 1375-1386.
[8]	XIE Xinliang, ZHOU Liping, YU Jianbo, XUAN Weidong, CHEN Chaoyue, WANG Jiang, REN Zhongming. Effect of Weak Transverse Magnetic Field on the Competitive Grain Growth of Ni-Based Superalloy with Divergent Bi-Crystals[J]. 金属学报, 2025, 61(8): 1203-1216.
[9]	HE Jiabao, WANG Liang, ZHANG Chaowei, ZOU Mingke, MENG Jie, WANG Xinguang, JIANG Sumeng, ZHOU Yizhou, SUN Xiaofeng. Effect of Al₂O₃ Coating on Interface Reaction Between Si-Based Ceramic Core and Ni-Based Single-Crystal Superalloy[J]. 金属学报, 2025, 61(7): 1093-1108.
[10]	WANG Feixiang, CHEN Zhongfeng, YIN Xiaoyu, XIONG Lianghua, XIE Honglan, DENG Biao, XIAO Tiqiao. In Situ Observation of Three-Dimensional Solidification Microstructure of Superalloy Melt Based on X-Ray Stereo Imaging[J]. 金属学报, 2025, 61(7): 1109-1118.
[11]	LI Yongmei, TAN Zihao, WANG Xinguang, TAO Xipeng, YANG Yanhong, LIU Jide, LIU Jinlai, LI Jinguo, ZHOU Yizhou, SUN Xiaofeng. Oxidation Behavior of a Low-Cost Third-Generation Ni-Based Single-Crystal Superalloy[J]. 金属学报, 2025, 61(7): 1049-1059.
[12]	LI Dayu, YAO Zhihao, ZHAO Jie, DONG Jianxin, GUO Jing, ZHAO Yu. Evolution of Microstructure and Mechanical Properties of FGH4720Li P/M Superalloy Under Near-Service Conditions[J]. 金属学报, 2025, 61(6): 826-836.
[13]	LI Xinyu, BAI Jiaming, ZHANG Haopeng, LI Xiaokun, JIA Jian, LIU Changsheng, LIU Jiantao, ZHANG Yiwen. Creep Behavior of Advanced Powder Metallurgy Nickel-Based Superalloys FGH4108 Under Different Stress Conditions[J]. 金属学报, 2025, 61(5): 757-769.
[14]	ZHOU Yiming, HAN Yongjun, XIE Guang, ZHENG Wei, XIAO Yanbin, PAN Yang, ZHANG Jian. High-Temperature Corrosion Behavior of a Nickel-Based Superalloy in HCl-Containing Atmosphere[J]. 金属学报, 2025, 61(5): 770-782.
[15]	ZHANG Haopeng, BAI Jiaming, LI Xinyu, LI Xiaokun, JIA Jian, LIU Jiantao, ZHANG Yiwen. Effect of Hf and Ta on Creep Rupture Characteristics and Properties of Powder Metallurgy Ni-Based Superalloys[J]. 金属学报, 2025, 61(4): 583-596.

No Suggested Reading articles found!

Viewed

Full text

Abstract

Cited

Shared

Discussed