Ultrasonic rolling-enhanced additive manufacturing of IN718 superalloy: Microstructural refinement and mechanical property improvement through variable power modulation

IF 11.1 1区 工程技术 Q1 ENGINEERING, MANUFACTURING
Hang Lin , Zhizhuo Li , Mingwang Fu , Hao Yi , Haiou Zhang , Runsheng Li
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引用次数: 0

Abstract

Conventional wire and arc direct energy deposition (WADED) of nickel-based superalloys faces critical challenges, such as, coarse columnar grains, pronounced elemental segregation, and suboptimal mechanical performance, hindering their applications in high-value aerospace industries. Herein, we developed an ultrasonic rolling-assisted WADED (UR-WADED) strategy that synergistically couples dynamic plastic deformation with in-situ ultrasonic vibration. Through systematic modulation of ultrasonic power (0–90 %), its effects on dendritic evolution, phase transformation, and dislocation dynamics were decoupled. Multiscale characterization revealed that ultrasonic mechanical excitation induced three key effects: (1) grain refinement was achieved through the combined effects of acoustic cavitation and rolling. Under high-power UR, a mixed grain structure was formed, and the average grain size in the fine-grained region was reduced by 80.5 % (from 178.68 μm to 34.87 μm); (2) The joint action of acoustic streaming and rolling transformed the morphology of the Laves phase from a continuous chain-like distribution into a more dispersed island-like form; (3) Texture randomization occurred, with the maximum intensity of the (001) pole figure reduced by 62 %, accompanied by the generation of a high density of intragranular dislocations. The optimized 90UR-WADED specimen exhibited significant property enhancement: Vickers hardness increased by 42.5 % (376.2 vs 264.1 HV0.5), while yield and ultimate tensile strengths surged to 768.2 (+55.5 %) and 1072.9 MPa (+38.9 %), respectively, outperforming conventional WADED counterparts. Quantitative strengthening analysis identified grain boundary strengthening (∼59 %) and dislocation hardening (∼23 %) as dominant mechanisms. After heat treatment, the 90UR-WADED sample exhibited a fully equiaxed grain structure, and its mechanical properties surpassed those of wrought IN718. This work established a notable hybrid manufacturing approach that overcomes the intrinsic limitations of arc-based additive manufacturing and provides a scalable pathway for fabricating high-performance superalloy components.
超声轧制增强增材制造IN718高温合金:通过变功率调制细化组织和提高力学性能
传统的镍基高温合金线弧直接能量沉积(WADED)技术面临着柱状晶粒粗大、元素偏析明显、力学性能欠佳等严峻挑战,阻碍了其在高价值航空航天工业中的应用。在此,我们开发了一种超声滚动辅助WADED (UR-WADED)策略,将动态塑性变形与原位超声振动协同耦合。通过系统调制超声功率(0-90 %),解耦了超声功率对枝晶演化、相变和位错动力学的影响。多尺度表征表明,超声机械激励诱导了三个关键效应:(1)通过声空化和滚动的联合作用实现晶粒细化。在高功率UR作用下,形成了混合晶粒结构,细晶区平均晶粒尺寸减小80.5 %(从178.68 μm减小到34.87 μm);(2)声流和声滚的共同作用使Laves相的形态由连续的链状分布转变为更分散的岛状形态;(3)纹理随机化,(001)极形的最大强度降低了62% %,同时产生了高密度的晶内位错。优化后的90hr -WADED试样性能显著增强:维氏硬度提高42.5 % (376.2 vs 264.1 HV0.5),屈服强度和极限抗拉强度分别达到768.2(+55.5 %)和1072.9 MPa(+38.9 %),优于常规WADED试样。定量强化分析确定晶界强化(~ 59 %)和位错硬化(~ 23 %)是主要机制。热处理后,90r - waded试样呈现出完全等轴的晶粒组织,其力学性能优于变形后的IN718。这项工作建立了一种显著的混合制造方法,克服了基于电弧的增材制造的固有局限性,并为制造高性能高温合金部件提供了可扩展的途径。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
Additive manufacturing
Additive manufacturing Materials Science-General Materials Science
CiteScore
19.80
自引率
12.70%
发文量
648
审稿时长
35 days
期刊介绍: Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.
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