Finite Element Simulation of Superplastic Isothermal Forging Process for Nickel-Base PM Superalloy

2007 ◽  
Vol 551-552 ◽  
pp. 297-302 ◽  
Author(s):  
Q.H. Li ◽  
Fu Guo Li ◽  
Q. Wan ◽  
Miao Quan Li
Keyword(s):  
Finite Element ◽  
Equivalent Stress ◽  
Turbine Disk ◽  
Cavity Surface ◽  
Yield Limit ◽  
Isothermal Forging ◽  
Forging Process ◽  
Die Material ◽  
Nickel Base ◽  
Pm Superalloy

The Chinese nickel-base powder metallurgy (PM) superalloy FGH96, which was processed through hot isostatic pressing, is very difficult to deform. FGH96 superalloy has better superplasticity in special deformation conditions and superplastic isothermal forging is the best formation method at present. The accurate constitutive equations of the FGH96 alloy was established depended on the isothermal compression experiments. A two dimensional and thermomechanical coupled axisymmetric finite element(FE) model in which both part and die were taken in consideration was established to fully simulate the FGH96 superalloy turbine disk superplastic isothermal forging process. Some physical parameters about the turbine disk forging process, such as load, stress field and strain field were calculated at different temperature within the forging range of FGH96. The regularity of peak equivalent stress acted on die cavity surface, yield limit and ultimate strength of die material during the forging process was found. Based on the regulation, peak equivalent stress acted on cavity surface must be extremely less than yield limit of die material, the optimized processing parameter 1050°C that is the best deformation temperature for the alloy was determined. That was proved better in practice and high quality disk was forged.

Effect of Ta on the Oxidation Resistance of a Cast Nickel-Base Die Material with Low Cr and High W Content

2005 ◽  
Vol 475-479 ◽  
pp. 669-672
Author(s):  
Qing Li ◽  
Cheng Bo Xiao ◽  
Jin Xia Song ◽  
Ding Gang Wang ◽  
Ya Fang Han
Keyword(s):  
Oxidation Resistance ◽  
Protective Layer ◽  
Mass Gain ◽  
Nickel Base Superalloy ◽  
Temperature Oxidation ◽  
Isothermal Forging ◽  
Oxidation Test ◽  
Die Material ◽  
Nickel Base ◽  
Forging Die

A conventional cast nickel-base superalloy with the chemical composition of Ni-16W-2Mo-1.5Cr-6Al wt % has been recently developed as isothermal forging die material operating at temperatures above 1000°C. The oxidation test results showed that the oxide scale spalled heavily after exposure in air at 1050°C for 100 h, which is unacceptable for the process of isothermal forging. To improve the high temperature oxidation resistance, 3 wt% Ta was added into the alloy. Specimens after oxidation test were analyzed by the scanning electron microscope (SEM) and the X-ray diffraction analysis (XRD). The results showed that the oxides were mainly NiO, NiWO4, and NiAl2O4 for all the samples. The oxidation resistance of the alloy with 3wt%Ta was fairly good at 1050°C with the mass gain rate of around 0.016g/m2•h and spallation of oxides less than 2g/m2 within 100h.The SEM results showed that a continuous protective layer of Al2O3 has been formed under the layer of NiO for the alloy containing Ta.

Forming Process Simulation and Optimization of Nickel-Base Superalloy Turbine Disk

2014 ◽  
Vol 1004-1005 ◽  
pp. 1156-1161 ◽  
Author(s):  
Wan Lin Zhou ◽  
Wen Hao Chen ◽  
Fu Jun Zhang
Keyword(s):  
Turbine Disk ◽  
Nickel Base Superalloy ◽  
Forming Process ◽  
Simulation And Optimization ◽  
Forging Process ◽  
Turbine Disks ◽  
Process Simulation And Optimization ◽  
Nickel Base ◽  
Hot Die Forging ◽  
Forming Methods

Turbine disc is the key component of aviation engine, its performance is important to ensure the reliability and safety of the whole aviation engine. In this paper, forging forming of GH4169 alloy turbine disks of certain type aero-engine are discsimulated by DEFORM-3D soft system,these forming methods include next three kinds: common hot die forging, isothermal forging and composite sheath hot die forging.The influences of various forging ways on turbine disk forging quality and the used die are analyzed in order to find the most suitable way of forging. The forging defects in the forging process are analyzed . For basically eliminating these defects, the forging process of superalloy turbine disk are optimized based on the most economical and simple principles and some useful methds are gained，which will provide a reference to actual superalloy turbine disk forging process.

3D Finite Element Analysis of Spider Non-isothermal Forging Process

2016 ◽  
Vol 25 (6) ◽  
pp. 2536-2541
Author(s):  
Ling Niu ◽  
Wei Wei ◽  
Kun Xia Wei ◽  
Igor V. Alexandrov ◽  
Jing Hu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Element Analysis ◽  
3D Finite Element ◽  
Isothermal Forging ◽  
3D Finite Element Analysis ◽  
Forging Process

Manufacturing of Nanostructured Blades for a Francis Turbine by Isothermal Forging of AA6063

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
D. Salcedo ◽  
C. J. Luis ◽  
J. León ◽  
I. Puertas ◽  
J. P. Fuertes ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Research Work ◽  
Francis Turbine ◽  
Compression Tests ◽  
Isothermal Forging ◽  
Forging Process ◽  
Different Temperatures ◽  
Traditional Approaches

This research work deals with the manufacturing of blades for a Francis turbine with a submicrometric structure through the isothermal forging of a heat-treatable aluminum alloy that has been previously processed by angular channel extrusion. In addition, mechanical properties and microstructure of these same blades are analyzed. A comparative study is also carried out between the properties obtained in the forged blades from the alloy previously deformed through angular channel extrusion and those obtained by employing two other isothermal forging processes of this alloy which mean utilizing different process stages. Moreover, a modeling by finite element about the isothermal forging process of the blades is performed using flow rules obtained from compression tests on these alloys at different temperatures. In this way, a much higher degree of accuracy is achieved in the results compared with that obtained through traditional approaches. With this present study, it is intended to make some progress in the development of nanostructured mechanical components with the aim of demonstrating the feasibility of their manufacturing and achieving an improvement in their mechanical properties.

Isothermal forging process design for spray-formed FGH95 superalloy turbine disk based on numerical simulation

Rare Metals ◽  
2013 ◽  
Vol 32 (4) ◽  
pp. 347-353 ◽  
Author(s):  
Biao Guo ◽  
Chuan-Sui Sun ◽  
Sui-Cai Zhang ◽  
Chang-Chun Ge
Keyword(s):  
Numerical Simulation ◽  
Process Design ◽  
Turbine Disk ◽  
Isothermal Forging ◽  
Forging Process ◽  
Fgh95 Superalloy

scholarly journals Finite Element Modeling of Residual Stress at Joint Interface of Titanium Alloy and 17-4PH Stainless Steel

Metals ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 629
Author(s):  
Nana Kwabena Adomako ◽  
Sung Hoon Kim ◽  
Ji Hong Yoon ◽  
Se-Hwan Lee ◽  
Jeoung Han Kim
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Stainless Steel ◽  
Finite Element Modeling ◽  
Equivalent Stress ◽  
Stress Gradient ◽  
Joint Interface ◽  
Element Modeling ◽  
Actual Experiment ◽  
Maximum Equivalent Stress

Residual stress is a crucial element in determining the integrity of parts and lifetime of additively manufactured structures. In stainless steel and Ti-6Al-4V fabricated joints, residual stress causes cracking and delamination of the brittle intermetallic joint interface. Knowledge of the degree of residual stress at the joint interface is, therefore, important; however, the available information is limited owing to the joint’s brittle nature and its high failure susceptibility. In this study, the residual stress distribution during the deposition of 17-4PH stainless steel on Ti-6Al-4V alloy was predicted using Simufact additive software based on the finite element modeling technique. A sharp stress gradient was revealed at the joint interface, with compressive stress on the Ti-6Al-4V side and tensile stress on the 17-4PH side. This distribution is attributed to the large difference in the coefficients of thermal expansion of the two metals. The 17-4PH side exhibited maximum equivalent stress of 500 MPa, which was twice that of the Ti-6Al-4V side (240 MPa). This showed good correlation with the thermal residual stress calculations of the alloys. The thermal history predicted via simulation at the joint interface was within the temperature range of 368–477 °C and was highly congruent with that obtained in the actual experiment, approximately 300–450 °C. In the actual experiment, joint delamination occurred, ascribable to the residual stress accumulation and multiple additive manufacturing (AM) thermal cycles on the brittle FeTi and Fe2Ti intermetallic joint interface. The build deflected to the side at an angle of 0.708° after the simulation. This study could serve as a valid reference for engineers to understand the residual stress development in 17-4PH and Ti-6Al-4V joints fabricated with AM.

The Effect of Isothermal Forging Process Parameters on the Microstructure and the Properties of TA15 Near α Titanium Alloy

2007 ◽  
Vol 26-28 ◽  
pp. 367-371
Author(s):  
Hong Zhen Guo ◽  
Zhang Long Zhao ◽  
Bin Wang ◽  
Ze Kun Yao ◽  
Ying Ying Liu
Keyword(s):  
Titanium Alloy ◽  
High Temperature ◽  
Tensile Properties ◽  
Process Parameters ◽  
Spherical Shape ◽  
Deformation Degree ◽  
Isothermal Forging ◽  
Forging Process ◽  
Α Phase ◽  
Strip Shape

In this paper the effect of isothermal forging process parameters on the microstructure and the mechanical properties of TA15 titanium alloy was researched. The results of the tests indicate that, in the range of temperature of 850 °C~980 °C and deformation degree of 20%~60%, with the increase of temperature or deformation, as the reinforcement of deformation recrystallization, the primary α-phase tends to the spherical shape and secondary α-phase transforms from the acicular shape to fine and spherical shape with disperse distribution, which enhance the tensile properties at room and high temperature. With the increment of forging times, the spheroidization of primary α-phase aggrandizes and secondary α-phase transforms from spherical and acicular shape to wide strip shape, which decrease the tensile properties at room and high temperature. The preferable isothermal forging process parameters are temperature of 980 °C, deformation degree of 60%, and few forging times.

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