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In this work, the quantification of key microstructural features like γ′ size morphology distribution, grain size, and localized stress distribution, especially near a fracture, were coupled with mechanical properties under various temperatures in Ni-base powder metallurgy superalloys subjected to sub-solvus or super-solvus heat treatments. Compared to super-solvus heat-treated alloy, sub-solvus heat-treated superalloy with a finer grain size exhibited higher ductility/strength at 550 °C, whilst adverse trend was observed at higher temperatures (750 and 830 °C). Besides, for both alloys, the strength and ductility decreased with the decrease in strain rate, resulting from oxidation behavior. Larger grain size or less grain boundary density can facilitate the retardation of oxidation behavior and weaken the propensity of early failure at higher temperatures.

A new third generation nickel-based powder metallurgy (PM) superalloy, designated as FGH100L, was prepared by spray forming. The effects of hot isostatic pressing (HIP) and isothermal forging (IF) processes on the creep performance, microstructure, fracture, and creep deformation mechanism of the alloy were studied. The microstructure and fracture were characterized by optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The coupled HIP and IF process improved the creep performance of the alloy under the creep condition of 705 °C/897 MPa. As for both the HIPed and IFed alloys, the creep process was dominated by the accumulation of dislocations and stacking faults, cutting through γ′ precipitates. The microstructural evolution was the main factor affecting the creep performance, which mainly manifested as coarsening, splitting, and morphology change of γ′ precipitates. Both the creep fractures of the HIPed and IFed alloys indicated intergranular fracture characteristics. In the former, wedge-shaped cracks usually initiated at the trigeminal intersection of the grain boundaries, while in the latter, cavity cracks generate more easily around the serrated curved grain boundary and carbides.

A modified FGH96 superalloy using 0.1 wt% graphene was successfully prepared using the wet mixing method. The interfacial bonding mechanism between the graphene and the superalloy matrix was characterized using optical microscope, scanning electronic microscope, transmission electronic microscope and X-ray tomography. The results revealed that the graphene could be dispersed uniformly inside the matrix of the superalloy, and the bonding interface between graphene and the superalloy showed a rather diffusion instead of abrupt distinction, suggesting that the interface was formed via chemical fusion rather than a mechanical combination. The uniform dispersity of the graphene inside the superalloy matrix could improve the tensile properties significantly, including tensile strength, plasticity and yield strength. The existence of the graphene at the fracture surface further verified that the graphene could increase the effective bearing force of the material during the tensile test.

The need for nickel-base powder metallurgy （PM） superalloy turbine discs is becoming increasingly evi dent. With the eventual aim of improving thrust-to-weight ratio of aeroengines for power generation, well integration of significantly high strength, high damage tolerance and high-temperature capability would be reasonably required. An advanced PM superalloy, which was designed for applications up to 815- 8 5 0 ℃, was experimentally investigated. Emphasis was primarily put on microstructure and mechanical properties. The results indicated the measured phases in the sample were composed of γ,γ＇, MC, and Ma B2. With uniform coarse grain microstruc ture （ASTM 5-6）, the sample appeared to exhibit overwhelming superiority over the prior art materials FGH95, FGH96, FGH97 and FGH98. The dominant embodiments consisted of high tensile strength （Rm = 1000 MPa and Rp0.2 800 MPa at 850℃）, strong creep resistance （ξp 0.12% at 815 ℃/400 MPa/50 h）, and considerable stressrupture life （τ=457.4 h at 815 ℃/450 MPa）. The technical practicability of applications up to 815-850 ℃ of this alloy was conclusively proved.

FGH95 nickel-based superalloy is produced by powder metallurgy (PM) processing for aerospace applications. Due to lower thermal conductivity, work hardening tendency during machining, and intensive adhesion to the surface of the tooling under operation, machining of FGH95 alloy is a significant challenges. The FGH95 machining process will induce substantial amount of plastic deformation in the surface and subsurface of the workpiece. A theoretical model is developed to predict the plastic deformation in machined surface of FGH95 superalloy. Experimental results are also applied to analyze the influence of cutting speed on plastic deformation in machined surface of FGH95. It is found that cutting speed has significantly effect on the plastic deformation in the machined surface. The increasing the cutting speed creates severer plastic deformation. Surface plastic shear strain increases with the increases of cutting speed, while the depth of plastic deformation decreases contrary.

Microstructure and properties of nickel based powder metallurgy （PM） superalloy were presented. Effects of nonmetallic inclusions and heat treatment on microstructure and properties were. discussed. Development tendency of microstructure and properties of PM superalloy was presented.

Four experimental FGH96 alloys with various contents of Hf and Zr （0 and 0.04%, 0.3% and 0.04%, 0.6% and 0. 04%, 0. 3% and 0.06%, respectively） were produced using PREP （plasma rotating electrode process）＋ HIP （hot isostatic pressing） route. The unnotched and notched stress-rupture properties and fatigue crack growth rate （FCGR） of all the experimental alloys were investigated to study the effect of Hf and Zr. Relevant fracture morphol ogy and microstructure were observed by scanning electron microscopy and transmission electron microscopy. The results revealed that appropriate content of Hf could lengthen stress-rupture life, eliminate notch sensitivity and slo wer FCGR. Microstructure analysis showed that the amount of ＂f phase should be increased or decreased by adjusting Hf and Zr contents, and MC carbide and oxide coupled growth should be increased by adding Hf content, which caused oxycarbide to precipitate along grain boundary and strengthen the alloy. It was found that excessive Zr in Hf- containing FGH96 alloy had certain deleterious effects on stress-rupture property because there was strong Zr segre- gation at prior particle boundary, leaving a long chain of large-size oxides along the boundary. The optimal content of Hf and Zr in FGH96 alloy was 0.6% and 0. 04%, respectively.

Powder metallurgy nickel-based superalloys have been widely used in high temperature applications. For these materials, a fully dense and fine-grained microstructure is important. Full densification can be achieved by a suitable processing technique, while the latter can be achieved through recrystallisation for which valuable guidance is provided by the information about recrystallisation nuclei. In this study, a fully dense powder metallurgy nickel-based superalloy component has been produced by a new manufacturing method—direct powder forging—using a single acting hydraulic press under normal atmosphere. Boundary misorientation of the produced material has been analysed to determine the degree of recrystallisation nucleation. A finite element model for direct powder forging has been developed in DEFORM-2D/3D and validated by comparing experimental and simulated load curves. The relationship of stress and strain state with densification and recrystallisation nucleation degree has been analysed. It was found that the direct powder forged FGH96 alloy has a much higher recystallisation nucleation degree and more recrystallised sub-grains, compared with those of the hot isostatic pressed material. Within the forged component, a higher recystallisation nucleation degree resides in the material near the container wall where greater values of shear strain rate have operated.

With the rapid development of modern aviation industry, dual-property turbine disc with fine comprehensive performance plays an important role in raising the thrust-to-weight ratio of the aero-engine. For manufacturing dual-property turbine disc, the powder metallurgy superalloy (PM) with excellent creep resistance was chosen as rim material, and the wrought superalloy with fine equiaxed grains was chosen as bore material. Electron beam welding was carried out on the PM/wrought dual superalloys. Hot compression tests were conducted on the PM/Wrought dual superalloys at temperatures of 1020–1140 °C and strain rates of 0.001–1.0 s−1. Deformation behavior and microstructure evolution have been investigated to study the deformation and recrystallization mechanism during hot deformation process. The results showed that PM/Wrought dual superalloy presents the similar flow behavior to single alloys and flow stress decreases significantly with the increase of deformation temperature or the decrease of strain rate. The apparent activation energy of deformation at the strain of 0.2 was determined as being 780.07 kJ·mol−1. The constitutive equation was constructed for modeling the hot deformation of PM/Wrought dual superalloy. Meanwhile, the processing map approach was further adopted to optimize the manufacturing process for the dual-property turbine disc. Additionally, a new instability criterion was proposed: the “cliff” and “valley” in the power dissipation map are determined as sufficient conditions for flow instability. The optimum processing parameter for manufacturing the PM/Wrought dual-property turbine disc can be obtained to enhance the mechanical properties, based on the analysis of processing map technology and microstructural mechanism.

The powder metallurgy (PM) nickel-base superalloy GH720 was extruded at 1100°C and the as-extruded samples were treated at 1110°C during 10min, 20min and 30min apart. The microstructure and recrystallization behavior of as-extruded alloy GH720 were discussed. The results indicate that there are two different types of γ' phases: primary γ' phase is mainly distributed on the grain boundary with an average size ranging from 0.3 to 0.5μm and dissolves partially at 1110°C during 30min, whereas the secondary γ' phase is distributed inside the grains with an average size of 50nm and dissolves largely at 1110°C during 30min. Recrystallization mechanism is subgrain nucleation when as-extruded GH720 is treated at 1110°C at which a lot of γ' phase exist. γ' phase inhibits growth of recrystallized grain availably and the uniform, fine and equiaxed grains in GH720 were formed during the extrusion and following heat treatment process.