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

高温合金，特别是镍基高温合金是喷气涡轮发动机涡轮部分使用最广泛的材料。这些合金中的绝大多数是通过锻造或更广泛地说，通过基于高温塑性变形的工艺生产的。控制从最初的钢锭破裂工序到精密零件的最终锻造的热加工过程，对于产生一致和优异的力学性能至关重要。因此，需要了解热变形工艺参数的影响，以控制零件的形状和最终的性能。即使优化了锻造工艺阶段，锻造零件也将需要一些最小的加工来生产最终零件；该项目包括一项研究，以选择合适的切割材料和设计加工时间表来生产最终零件。在这项与GE Canada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，它被描述为“未来一代合金”。该项目的主要目标将是(1)确定该合金的基本热变形特征，即抗热变形能力和对显微组织的影响；(2)开发能够预测其在工业热加工条件下的演变的微观结构模型。(3)了解显微组织对使用中机械性能的影响，特别是疲劳、高温强度和蠕变抗力；(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来加工锻件；(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)优化加工条件和(9)使用在阶段(4)中设计的变量为Rene 65加工提出加工条件。

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).