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

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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).****