Forging and machining process design for nickel superalloy rene65 for use in compressor blades

压缩机叶片用镍高温合金rene65的锻造和加工工艺设计

• 批准号: 485659-2015
• 负责人: Yue, Stephen
• 金额: $ 2.21万
• 依托单位: McGill University
• 依托单位国家: 加拿大
• 项目类别: Collaborative Research and Development Grants
• 财政年份: 2017
• 资助国家: 加拿大
• 起止时间: 2017-01-01 至 2018-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=618420
• 关键词: Forging; machining; process; design; nickel

Superalloys and particularly nickel-base superalloys are the most extensively used materials in the turbine section of jet turbine engines. The great majority of these alloys are produced via forging or, more generally, from an elevated temperature plastic deformation based process. The control of the hot-working processes from the initial ingot breakdown procedures to the final forging of precision components is critical for the generation of consistent and superior mechanical properties. Thus understanding the influence of the hot deformation process parameters is required to control the shape of the component and the final properties. Even if the forging process stage is optimized, the as-forged component will require some minimal machining to produce the final part; this project includes a study to select suitable cutting materials and to design machining schedules to produce the final part. In this proposal, which is in collaboration with GE Canada and A7 Integration, the alloy to be studied is the newest nickel-based superalloy, Rene65, which has been described as a 'future-generation alloy'. The main objectives of the project will be to (1) determine the basic hot deformation characteristics of this alloy with respect to the resistance to hot deformation and the effect on microstructure; (2) to develop microstructural models capable of predicting its evolution under industrial hot working conditions. (3) to understand the effect of microstructure on in service mechanical properties, in particular fatigue, elevated temperature strength and creep resistance; (4) to be able to design the entire industrial hot working process including all heat treatments to produce the desired shape and properties; (5) to select appropriate cutting tool materials and coatings to finish machine the forged part; (6) determine the effect of machining process parameters on the performance of the selected cutting tool materials (7) conduct machining tests collect machining data necessary for determining the Taylor's tool Life model coefficients and for optimising the cutting tool performances, (8) Optimise the machining conditions and (9) Suggest machining conditions for Rene 65 processed using variables designed in stage (4).

高温合金，特别是镍基高温合金是喷气涡轮发动机涡轮部件中应用最广泛的材料。这些合金绝大多数是通过锻造生产的，或者更一般地说，是通过高温塑性变形工艺生产的。从最初的钢锭击穿过程到精密部件的最终锻造，热加工过程的控制对于产生一致和卓越的机械性能至关重要。因此，了解热变形工艺参数的影响是控制零件形状和最终性能的必要条件。即使锻造工艺阶段是优化的，作为锻造的部件将需要一些最小的加工来生产最终零件；该项目包括研究选择合适的切削材料和设计加工计划，以生产最终零件。在这项与通用电气加拿大公司和A7集成公司合作的提案中，要研究的合金是最新的镍基高温合金Rene65，这被称为“下一代合金”。该项目的主要目标是：(1)确定该合金的基本热变形特性，包括抗热变形和对显微组织的影响；(2)建立能够预测其在工业热工况下演变的微观组织模型。(3)了解微观结构对使用力学性能的影响，特别是疲劳、高温强度和抗蠕变性能；(4)能够设计整个工业热加工过程，包括所有热处理，以产生所需的形状和性能；(5)选择合适的刀具材料和涂层对锻件进行精加工；(6)确定加工工艺参数对所选刀具材料性能的影响；(7)进行加工试验，收集确定泰勒刀具寿命模型系数和优化刀具性能所需的加工数据；(8)优化加工条件；(9)使用阶段(4)设计的变量建议加工Rene 65的加工条件。