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In most chemical and high-temperature processes, metals are exposed to temperature gradients which, in turn, affect the extent of corrosion phenomena. In this study, a long, continuous strip of alloy 625 was exposed to lithium fluoride in a temperature range of 50–600 °C, air environment. The hottest section of this strip was analyzed as a coupon and compared with two other coupons which were exposed isothermally. One of the isothermal exposures was carried out in a tube furnace, and the other one was in a vertical furnace. Oxygen had three different kinds of access to these three coupons, which, in turn, affected the corrosion process. In order to limit the access of oxygen, a long column of lithium fluoride was used in a vertical furnace. The results of the isothermal exposure showed that more access of oxygen in a horizontal tube furnace facilitated the fluoride ingress to a great extent. However, a long sample exposed to a temperature gradient suffered more corrosion attack than the isothermal coupon, under the same LiF load in the vertical furnace. This was associated with the reduction of oxygen at a larger cathode area reaching into colder regions in Inconel 625 strip. Increased oxygen reduction also increases the efficiency of an inner anode at the hottest section, causing the observed rapid intergranular fluoride uptake. The study proposes a mechanism explaining these observations.

The Hugoniot elastic limit and spall strength were measured for a heat-resistant metal-matrix composite Inconel 625–5%NiTi–TiB2 alloy additive manufactured (AM) by direct laser deposition. The strength characteristics of the alloy were obtained from the analysis of the complete wave profiles recorded with a VISAR laser Doppler velocimeter during shock-wave loading of the samples. The samples were loaded using a PP50 pneumatic gun or ad hoc explosive devices along and across the material deposition direction in order to determine the strength anisotropy of the AM alloy under study. The maximum shock compression pressure was ~7 GPa, and the strain rate under tension before spalling varied in the range of 105–106 s–1. Kinetic dependencies of elastic/plastic transition and critical fracture stresses vs. loading conditions were plotted. It was shown that the Hugoniot elastic limit of the alloy under study decreases as the shock wave travels into the sample, while the spall strength increases as the material’s strain rate increases at the moment of spall fracture. A comparison of the strength characteristics of the Inconel 625–NiTi–TiB2 composite alloy with the original Inconel 625 alloy has shown that an addition of 5% of powder based on NiTi-TiB2 leads to a decrease in its elastic limit and critical fracture stresses upon spalling by more than 10%. The alloy under study demonstrates anisotropy of strength properties relative to the material deposition direction.

Wire + arc additive manufacturing (WAAM) is a versatile, low-cost, energy-efficient technology used in metal additive manufacturing. This WAAM process uses arc welding to melt a wire and form a three-dimensional (3D) object using a layer-by-layer stacking mechanism. In the present study, a Ni-based superalloy wire, i.e., Inconel 625, is melted and deposited additively through a cold metal transfer (CMT)-based WAAM process. The deposited specimens were heat-treated at 980 °C (the recommended temperature for stress-relief annealing) for 30, 60, and 120 min and then water quenched to investigate the effect of heat treatment on microstructure and phase transformation and to identify the optimum heat treatment condition. Microstructural results show that the heat treatment, in general, eliminates the brittle Laves phases regardless of the time without changing the grain morphology. However, an increment in the amount of the delta phase is observed with the longer heat treatment periods. Additionally, the size of MC (metal carbide) of Nb is also observed to increase with heat treatment time. This study provides an in-depth understanding of the correlation between heat treatment time and microstructure in additively manufactured Inconel 625, which can facilitate determining the optimum heat treatment condition in a later study.

Nickel-based superalloys, namely INCONEL® variants, have had an increase in applications throughout various industries like aeronautics, automotive and energy power plants. These superalloys can withstand high-temperature applications without suffering from creep, making them extremely appealing and suitable for manufactured goods such as jet engines or steam turbines. Nevertheless, INCONEL® alloys are considered difficult-to-cut materials, not only due to their superior material properties but also because of their poor thermal conductivity (k) and severe work hardening, which may lead to premature tool wear (TW) and poor final product finishing. In this regard, it is of paramount importance to optimise the machining parameters, to strengthen the process performance outcomes concerning the quality and cost of the product. The present review aims to systematically summarize and analyse the progress taken within the field of INCONEL® machining sensitively over the past five years, with some exceptions, and present the most recent solutions found in the industry, as well as the prospects from researchers. To accomplish this article, ScienceDirect, Springer, Taylor & Francis, Wiley and ASME have been used as sources of information as a result of great fidelity knowledge. Books from Woodhead Publishing Series, CRC Press and Academic Press have been also used. The main keywords used in searching information were: “Nickel-based superalloys”, “INCONEL® 718”, “INCONEL® 625” “INCONEL® Machining processes” and “Tool-wear mechanisms”. The combined use of these keywords was crucial to filter the huge information currently available about the evolution of INCONEL® machining technologies. As a main contribution to this work, three SWOT analyses are provided on information that is dispersed in several articles. It was found that significant progress in the traditional cutting tool technologies has been made, nonetheless, the machining of INCONEL® 718 and 625 is still considered a great challenge due to the intrinsic characteristics of those Ni-based-superalloys, whose machining promotes high-wear to the tools and coatings used.

The Inconel 625 (IN625) superalloy has a high strength, excellent fatigue, and creep resistance under high-temperature and high-pressure conditions, and is one of the critical materials used for manufacturing high-temperature bearing parts of aeroengines. However, the poor workability of IN625 alloy prevents IN625 superalloy to be used in wider applications, especially in applications requiring high geometrical complexity. Laser powder bed fusion (LPBF) is a powerful additive manufacturing process which can produce metal parts with high geometrical complexity and freedom. This paper reviews the studies that have been done on LPBF of IN625 focusing on the microstructure, mechanical properties, the development of residual stresses, and the mechanism of defect formation. Mechanical properties such as microhardness, tensile properties, and fatigue properties reported by different researchers are systematically summarized and analyzed. Finally, the remaining issues and suggestions on future research on LPBF of IN625 alloy parts are put forward.

Purpose This article targeted to experimentally examine the impact of several considered process parameters namely, applied voltage (AV), tool feed rate, electrolyte concentration and pulse frequency (PF), on the material removal rate (MRR) and radial overcut (ROC) while performing shaped tube drilling of aviation grade Inconel 625 super alloy through electrochemical machining principle. Further, an attempt has also been made to develop mathematical models for the process responses along with advanced optimization with evolutionary methods. Design/methodology/approach The central composite rotatable design matrix was used to scheme out the experiments in the present study. The consistency and accuracy of the developed mathematical models were confirmed through statistical results. Additionally, a field emission scanning electron microscope analysis was conducted to assess and analyze the microstructure of the machined work samples. The study also seeks to optimize the selected process inputs for MRR and ROC through the implementation of the desirability method, particle swarm optimization (PSO) and Teaching Learning-Based Optimization (TLBO). Findings The ROC is significantly influenced by the input parameters, specifically the PF and AV. Less ROC values were observed when the high PF with moderate AV. The minimum and maximum values of ROC and MRR were obtained as; 135.128 µm and 380.720 µm; 1.37 mg/min and 2.3707 mg/min, correspondingly. The best optimized confirmatory results were obtained through the TLBO approach, with an MRR value of 3.1587 mg/min and a ROC of 71.9629 µm, in comparison to the PSO and desirability approaches. Originality/value The various challenges associated with the productive machining of aviation grade Inconel 625 superalloy have been explored experimentally. The conducted experimentation has been performed on the in-house fabricated micro-electrochemical setup capable of performing a variety of advanced machining operations at the miniaturized level. Further, the application of shaped tube drilling while processing aviation grade Inconel 625 superalloy has been explored with the developed micro-ECM set-up. Moreover, the performed microstructure analysis of the machined work samples has elaborated and explored the various associated surface integrity aspects which are quite crucial when it comes to real-life aerospace-related applications. The utility of designed experiments has further made the attempted experimental analysis more fruitful and qualitative too.

Production rate is an increasingly important factor in the deployment of metal additive manufacturing (AM) throughout industry. To address the perceived low production rate of metal AM systems based on single-laser powder bed fusion (L-PBF), several companies now offer systems in which melting has been parallelised by the introduction of multiple, independently controlled laser beams. Nevertheless, a full set of studies is yet to be conducted to benchmark the efficiency of multi-laser systems and, at the same time, to verify if the mechanical properties of components are compromised due to the increase in build rate. This study addresses the described technology gaps and presents a 4-beam L-PBF system operating in “single multi” (SM) mode (SM-L-PBF) where each of the four lasers is controlled so that it melts all of a particular components’ layers and produces specimens for comparison with standard L-PBF specimens from the same machine. That is all four lasers making all of some of the parts were compared to a single-laser manufacturing all of the parts. Build parameters were kept constant throughout the manufacturing process and the material used was Inconel 625 (IN625). Stress-relieving heat treatment was conducted on As-built (AB) specimens. Both AB and heat-treated (HT) specimen sets were tested for density, microstructure, tensile strength and hardness. Results indicate that the stress-relieving heat treatment increases specimen ductility without compromising other mechanical properties. SM-L-PBF has achieved a build rate of 14 cm 3 /h when four 200 W lasers were used to process IN625 at a layer thickness of 30 μm. An increase in the build rate of 2.74 times (build time reduction: 63%) has been demonstrated when compared to that of L-PBF, with little to no compromises in specimen mechanical properties. The observed tensile properties exceed the American Society for Testing Materials (ASTM) requirements for IN625 (by a margin of 22 to 26% in the 0.2% offset yield strength). Average specimen hardness and grain size are in the same order as that reported in literatures. The study has demonstrated that a multi-laser AM system opens up opportunities to tackle the impasse of low build rate in L-PBF in an industrial setting and that at least when operating in single mode there is no detectable degradation in the mechanical and crystallographic characteristics of the components produced.

The present study utilizes a slurry-pot wear tester to investigate the relationship between slurry concentration and slurry-erosion performance of sDSS 2507/IN625 dissimilar weld joint (DWJ). Varying slurry concentrations (10 and 30 wt.% silica sand) were utilized to investigate erosion, weight loss, and wear mechanisms in severe environments. The study aimed to provide an in-depth knowledge of erosion behaviors by analyzing surface characteristics, microstructure characteristics, and material removal mechanisms. The electron probe micro-analyzer studied weld zone element segregation and scanning electron microscopy (SEM) examined microstructure and erosion mechanism. ER2594 filler weld shows higher microhardness as compared to weld fabricated using ERNiCrMo-3 filler metal. Sand particle density, particle-to-surface contact, particle interactions, and fluid impacts increase cumulative weight loss and decrease erosion rate per unit solids weight. Slurry concentration increased weight loss by 23% for sDSS 2507 BM and 33% for IN-625 BM. ER2594-LHI lost 72% and ERNiCrMo-3-LHI 77% more weight with increasing slurry concentration. Filler ERNiCrMo-3 has less erosion wear than filler ER2594 as the concentration of slurry increases. SDSS 2507 BM and IN-625 BM erode 1.45 and 1.8 times faster with increasing slurry concentration, respectively. The erosion rate of ER2594-LHI and ERNiCrMo-3-LHI increases 0.85 and 1.2 times with slurry concentration. SEM analysis of the worn surface exhibits mixed cutting–ploughing modes coexisting with the formation of craters. The material removal has predominantly occurred from the cutting and ploughing mechanism, whereas the characteristic presence of craters and frontal and lateral lips is also found across the entire surface. The results from this study suggest the optimum heat input to be maintained during weld fabrication of sDSS 2507/IN-625 using ER 2594 and ERNiCrMo-3 filler metals for enhanced resistance against slurry erosion wear. Also, an insight into the wear mechanism helps in understanding the effect of microstructural features on the wear performance of welds in operational conditions.