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

超合金，特别是镍基超合金是喷气涡轮机发动机的涡轮机部分中最广泛使用的材料。这些合金中的绝大多数通过锻造或更一般地通过基于高温塑性变形的工艺生产。从最初的铸锭分解过程到精密部件的最终锻造，对热加工过程的控制对于产生一致和上级的机械性能至关重要。因此，需要了解热变形工艺参数的影响，以控制组件的形状和最终性能。即使锻造工艺阶段得到优化，锻造后的部件也需要进行最小限度的机加工来生产最终部件;该项目包括选择合适的切削材料和设计机加工计划以生产最终部件的研究。在这项与GE Canada和A7 Integration合作的提案中，要研究的合金是最新的镍基高温合金Rene 65，它被描述为“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，包括热变形抗力和对微观结构的影响;（2）开发能够预测其在工业热加工条件下演变的微观结构模型。(3)了解微观结构对使用中机械性能的影响，特别是疲劳、高温强度和抗蠕变性;（4）能够设计整个工业热加工工艺，包括所有热处理，以产生所需的形状和性能;（5）选择适当的切削工具材料和涂层，以精加工锻造零件;（6）确定加工工艺参数对所选切削刀具材料的性能的影响（7）进行加工试验，收集确定泰勒刀具寿命模型系数和优化切削刀具性能所需的加工数据，（8）优化加工条件和（9）建议使用阶段（4）中设计的变量加工的Rene 65的加工条件。

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).