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PL
W artykule przedstawiono zagadnienia związane z inżynierią materiałową, ceramiką i odlewnictwem precyzyjnym. Opisano historię i przebieg procesu odlewania detali i części silników lotniczych metodą traconego wosku. Manuskrypt zawiera również generalne informacje o spoiwach, proszkach, masach formierskich, formach odlewniczych i nadstopach niklu. Zaprezentowano podstawowe dane o spoiwach zawierających nanocząstki ceramiczne, modelach woskowych, na które nanoszone są masy lejne oraz o SiC - jednym z perspektywicznych proszków formierskich.
EN
The paper presents the main issues related to materials engineering and technology, ceramics and precision casting process. The history and methodology of the lost-wax casting process of elements and aircraft engine parts is described. The manuscript also contains general information on binders, powders, molding compounds, foundry molds and nickel superalloys. Basic data on binders containing ceramic nanoparticles, wax models and SiC - one of the prospective molding powders are presented.
EN
In this paper, disruption of brazing process impact on behavior of filler metal and properties of the joint was investigated. Hastelloy X sheet samples were brazed using Ni-13Cr-4Fe-4Si-2,7B filler alloy. Two identical sets of samples were heated in high vacuum, once load reached specified temperature process was interrupted. Subsequently, one set of samples was tested and second set was subjected to rebrazing in proper time and temperature, dedicated for used filler material. Disruption of the process in following temperature was analyzed: 930, 960, 1050, 1127, 1145, 1170°C. After both processes macroscopic observations of joint, peel test, static tensile test and spreadability analysis were carried out.
PL
W artykule przedstawiono wyniki badań odporności na korozję wżerową napoin z nadstopu niklu Alloy 59 w syntetycznym roztworze, symulującym środowisko pracy charakterystyczne dla skruberów FGD. Wykonano testy laboratoryjne, które polegały na umieszczeniu próbki w roztworze o zadanej temperaturze na 24 godziny. Przyjęto temperaturę początkową 90 °C, a następnie zwiększano o 5 °C w kolejnym badaniu, aż do pojawienia się wżerów korozyjnych. Za miarę odporności na korozję wżerową przyjęto obecność w materiale ubytków korozyjnych oraz zmiany masy. Na podstawie wyników przeprowadzonych badań wyznaczono krytyczną temperaturę korozji wżerowej (CPT – ang. Critical Pitting Temperature) napoin na poziomie 100 °C.
EN
This article presents the results of pitting corrosion resistance tests of padding welds made of nickel superalloy Alloy 59 in a Green Death solution, which simulate FGD scrubber environment. In the laboratory tests the specimens were placed in the solution at a given temperature per 24 hours. The initial temperature was set at 90 °C and then increased by 5 °C in the next test, until corrosion pits appeared. A visual examination of specimens surfaces, along with mass loses were performed to characterize the pitting resistance of material. On the basis of the results, the critical pitting temperature (CPT) of padding welds at a level of 100 °C was determined.
EN
The paper presents an attempt of application of the acoustic birefringence coefficient for early stage degradation assessment of Inconel 718 nickel superalloy after short-term creep. It is shown that it can serve as a good damage sensitive parameter and, moreover, it can be well correlated with hardness variation.
5
Content available remote Skłonność do pękania gorącego złączy spawanych z nadstopu niklu Inconel 617
PL
W pracy przedstawiono wyniki oceny skłonności do pękania gorącego nadstopu niklu Inconel 617. Badania przeprowadzono na blachach o grubości 1, 3 oraz 5 mm wykorzystując próbę Houldcrofta w warunkach zmiennej sztywności złącza. W próbie Houldcrofta, używając nietopliwej elektrody w osłonie gazów obojętnych, wykonano przetopienia stopu Inconel 617 z materiałem dodatkowym i bez materiału dodatkowego. W próbie wyznaczono wskaźnik A rozumiany jako stosunek długości pęknięcia do długości próbki, który jest wyrażany w procentach. Badania zostały uzupełnione o analizę metalograficzną i fraktograficzną, mikroanalizę składu chemicznego EDS z powierzchni pęknięcia oraz powierzchni prostopadłej do kierunku spawania. Uzyskane wyniki pozwoliły na opisanie mechanizmu pękania złączy spawanych z nadstopu niklu Inconel 617.
EN
The paper presents the results of the propensity of hot cracking of the nickel superalloy Inconel 617. The tests were carried out on nickel sheets with a thickness of 1, 3 and 5 mm using a Houldcroft’s test in variable stiffness of the welded joint. In Houldcroft’s test by using tungsten electrode in inert gas, remelting alloy Inconel 617 with additional material without additional material were made. In test the indicator A was designated, understood as the ratio of the crack length to the length of the sample, which is expressed as a percentage. Studies have been complemented by metallographic and fractography analysis, also made microanalysis of the chemical composition EDS of the crack surface and the surface, which is perpendicular to the direction of welding. The results allowed to describe the hot cracking mechanism of welded joints of nickel superalloy Inconel 617.
6
PL
Odlewy precyzyjne ze stopu Inconel 713C znalazły zastosowanie na elementy silników lotniczych pracujących w wysokich temperaturach oraz w agresywnym środowisku spalin. Praktyka przemysłowa wykazała, że w procesie odlewnia precyzyjnego, tak skomplikowanych elementów, pojawiają się wady odlewnicze w postaci rzadzizn, porowatości oraz pęknięć. Powoduje to konieczność opracowania technologii naprawy tego typu odlewów. W pracy przedstawiono wyniki badań metalograficznych napoin na nadstopie niklu Inconel 713C, wykonanych laserem oraz za pomocą napawania plazmowego. Proces napawania prowadzono na modelowych płytach próbnych, w celu określenia problemów technologicznych i materiałowych związanych ze spawalnością stopu Inconel 713C. Badania obejmowały analizę makro i mikrostruktury napoiny, materiału rodzimego i strefy wpływu ciepła. Wyniki badań strukturalnych obszarów napoin wskazują, że stop Inconel 713C należy zaliczyć do materiałów trudno spawalnych. W napoinach wykonanych laserowo ujawniono pęknięcia materiału głównie w strefie wpływu ciepła oraz na linii wtopienia, gdzie na nadtopionych ziarnach krystalizują kryształy napoiny. Tego typu pęknięć nie obserwowano w napoinach wykonanych plazmowo. Stwierdzono, ze względu na możliwość ręcznego napawania oraz brak niezgodności spawalniczych, technologią o większym potencjale zastosowania jest napawanie plazmowe.
EN
Inconel 713C precision castings are used as aircraft engine components exposed to high temperatures and the aggressive exhaust gas environment. Industrial experience has shown that precision-cast components of such complexity contain casting defects like microshrinkage, porosity, and cracks. This necessitates the development of repair technologies for castings of this type. This paper presents the results of metallographic examinations of pad welds on the Inconel 713C nickel-based superalloy, made by laser and by plasma-arc pad welding. The pad welding process was carried out on model test panels in order to determine the technological and material-related problems connected with the weldability of the Inconel 713C alloy. The studies included analyses of the macro and microstructure of the pad welds, the base materials, and the heat-affected zones. The results of the structural analyses of the pad welds indicate that Inconel 713C should be classified as a low-weldability material. In the pad welds made by laser, cracks were identified mainly in the heat-affected zone and at the melted zone interface, where pad weld crystals formed on partially-melted grains. Cracks of this type were not identified in the pad welds made using the plasma-arc method. It has been concluded that due to the possibility of manual pad welding and the absence of welding imperfections, the technology having the greater potential for application is plasma-arc pad welding.
PL
W pracy przedstawiono wyniki badań przeprowadzonych w celu oceny przydatności nieniszczących badań penetracyjnych w zastosowaniu do badania złączy spawanych wykonanych na superstopie niklu Inconel 713C. Jako metodę odniesienia wykorzystano obserwacje mikroskopowe. Stwierdzono, że metoda penetracyjna nie ujawniła wszystkich pęknięć wykrytych podczas obserwacji mikroskopowych.
EN
The paper presents results of the research performed in order to examine the eficiency of using of penetrant testing method to detect welding defects in welding joints made of Inconel 713C alloy. As a reference method, the microscopic observations have been used. It has been found that the penetrant testing method does not reveal all the cracks which can be detected using microscopic observations.
EN
The paper presents results of calorimetric studies of foundry nickel superalloys: IN100, IN713C, Mar-M247 and ŻS6U. Particular attention was paid to determination of phase transitions temperatures during heating and cooling. The samples were heated to a temperature of 1500°C with a rate of 10°C min–1 and then held at this temperature for 5 min. After a complete melting, the samples were cooled with the same rate. Argon with a purity of 99.99% constituted the protective atmosphere. The sample was placed in an alundum crucible with a capacity of 0.45 cm3. Temperature and heat calibration was carried out based on the melting point of high-purity Ni. The tests were carried out by the differential scanning calorimetry (DSC) using a Multi HTC high-temperature calorimeter from Setaram. Based on the DSC curves, the following temperatures were determined: solidus and liquidus, dissolution and precipitation of the γ’ phase, MC carbides and melting of the γ’/γ eutectic. In the temperature range of 100-1100°C, specific heat capacity of the investigated superalloys was determined. It was found that the IN713C and IN100 alloys exhibit a higher specific heat while compared to the Mar-M247 and ŻS6U alloys.
PL
Konieczność podnoszenia wydajności bloków energetycznych podyktowana jest zaostrzeniem przepisów przez Unię Europejską, dotyczących ograniczenia emisji CO2 do atmosfery. Wraz z podniesieniem ciśnienia i temperatury zaistniała potrzeba zastąpienia konwencjonalnych materiałów nowymi. na m. in. wymienniki ciepła zbudowane z rur ożebrowanych. Materiałami takimi są nadstopy niklu typu Inconel. W artykule przedstawiono wyniki badań odporności na korozję wysokotemperaturową złączy spawanych laserowo rur ożebrowanych wykonanych ze stopów niklu Inconel 600 oraz 625. Złącza poddano działaniu gazów symulujących spaliny w temperaturze 800 °C. Badania odporności na korozję przeprowadzono w czasie do 1000 godzin, wykonując pomiary przyrostu masy produktów korozji co 250 godzin. Dodatkowo wykonano badania metalograficzne – obserwacja na elektronowym mikroskopie skaningowym. W celu identyfikacji produktów korozji wykonano mikroanalizę składu chemicznego EDS oraz identyfikację składu fazowego metodą XRD. W trakcie badania ujawniono występowanie szczelnej warstwy zgorzeliny składającej się w większości z tlenku chromu. Wszystkie badane złącza charakteryzowały się wysoką odpornością na korozje wysokotemperaturową.
EN
The necessity of improving the efficiency of power units is dictated by the tightening of regulations by the European Union regarding the reduction of CO2 emissions into the atmosphere. Increasing of pressure and temperaturę eventuate in need for the replacement of conventional materials with new ones. inter alia for heat exchangers constructed with finned tubes. One of the most up and comming materials are Inconel nickel superalloys. This article presents results of research on high-temperature corrosion resistance laser-welded joints of finned tubes made of nickel alloy Inconel 600 and 625. Welded joints subjected to influence of simulated exhaust gas at a temperature of 800 °C. Weight gain measurements of corrosion products executed every 250 hours. Additionally, executed a metallographic observation on scanning electron microscope in order to identified the corrosion products made microanalysis of chemical composition EDS and identification phase composition by XRD. Tight layer of scale covering examined finned tubes mostly consisted of chromium oxide. All examined welded-joints characterized by high resistance to high-temperature corrosion.
EN
Paper presents the assessment of impact of heat treatment on durability in low-cycle fatigue conditions (under constant load) in castings made using post-production scrap of MAR-247 and IN-713C superalloys. Castings were obtained using modification and filtration methods. Additionally, casting made of MAR-247 were subjected to heat treatment consisting of solution treatment and subsequent aging. During low-cycle fatigue test the cyclic creep process were observed. It was demonstrated that the fine-grained samples have significantly higher durability in test conditions and , at the same time, lower values of plastic deformation to rupture Δ□pl. It has been also proven that durability of fine-grained MAR-247 samples can be further raised by about 60% using aforementioned heat treatment.
PL
W pracy przedstawiono wyniki badań prowadzonych nad opracowaniem procesu wytwarzania metodą zawiesinową żaroodpornych warstw Al-Si na podłożu nadstopu niklu Inconel 617. Elementy z naniesioną zawiesiną wygrzewano w piecu w atmosferze powietrza. Warstwy wytwarzano, stosując temperaturę wygrzewania 1000°C i 1100°C oraz czas wygrzewania 3 i 6 godzin. Wytwarzane warstwy cechuje budowa dwustrefowa. Dla uzyskanych warstw określono skład fazowy i chemiczny oraz morfologię składników fazowych mikrostruktury. Wykonano także pomiary grubości i twardości wytworzonych warstw.
EN
This paper presents results of research of aluminium-silicon coatings created by slurry method on nickel alloy Inconel 617. Samples covered with the slurry were annealed in air atmosphere. Technological parameters of coatings manufacturing were changed, i.e. annealing temperature 1000 and 1100°C, and time 3 or 6 h. The structure of obtained coatings is double-layer. The obtained coatings were investigated using: SEM, EDS, XRD methods. The thickness and microhardness tests of coatings were also performed.
EN
The paper presents the results of studies to determine the effect of complex surface and bulk modification and double filtration during mould pouring on the stereological parameters of macrostructure and mechanical properties of castings made from the post-production waste IN-713C and the MAR-247 nickel alloys. The evaluation covered the number of grains per 1mm2 of the sample surface area, the average area of grains and the shape index, hardness HB, tensile strength and resistance to high temperature creep. The results indicate the possibility of controlling the stereological parameters of macrostructure through application of several variants of the modification, controlling in this way also different low- and high-temperature properties. The positive effect of double filtration of the alloy during mould pouring on the metallurgical quality and mechanical properties of castings has also been emphasized.
EN
Impact of surface and volume modification and double filtration during pouring the moulds on basic mechanical properties and creep resistance of nickel superalloys IN-713C and MAR-247 in conditions of accelerated creep of castings made of post-production scrap of these alloys is evaluated in this paper. The conditions of initiation and propagation of cracks in the specimens were analysed with consideration of stereological properties of material macro- and microstructure. It has been proven that in the conditions of high-temperature creep at 980 C and at stress [...] = 150 MPa, creep resistance of superalloy MAR-247 is more than 10 times higher than the creep resistance of IN-713C alloy. In case of IN-713C alloy, the creep resistance negligibly depends on macrograin sizes. But, the macrograin size considerably affects the time to failure of specimens made of alloy MAR-247. Creep resistance of specimens made of coarse grain material was 20% higher than the resistance of fine grain materials.
EN
The paper presents the results of evaluation of the metallurgical quality of master heat ingots and of the identification of non-metallic inclusions (oxides of Al., Zr, Hf, Cr, etc.), which have been found in the shrinkage cavities formed in these ingots. The inclusions penetrate into the liquid alloy, and on pouring of mould are transferred to the casting, especially when the filtering system is not sufficiently effective. The specific nature of the melting process of nickel and cobalt alloys, carried out in vacuum induction furnaces, excludes the possibility of alloy refining and slag removal from the melt surface. Therefore, to improve the quality of castings (parts of aircraft engines), it is so important to evaluate the quality of ingots before charging them into the crucible of an induction furnace. It has been proved that one of the methods for rapid quality evaluation is an ATD analysis of the sample solidification process, where samples are taken from different areas of the master heat ingot. The evaluation is based on a set of parameters plotted on the graph of the dT/dt derivative curve during the last stage of the solidification process in a range from TEut to Tsol.
EN
The paper presents the method of manufacturing casts made of the IN-713C nickel superalloy using the wax lost investment casting process and silicon carbide chills. The authors designed experimental casts, the gating system and selected the chills material. Wax pattern, ceramic shell mould and experimental casts were prepared for the purposes of research. On the basis of the temperature distribution measurements, the kinetics of the solidification process was determined in the thickened part of the plate cast. This allowed to establish the quantity of phase transitions which occurred during cast cooling process and the approximate values of liquidus, eutectic, solidus and solvus temperatures as well as the solidification time and the average value of cast cooling rate. Non-destructive testing and macroscopic analysis were applied to determine the location and size of shrinkage defects. The authors present the mechanism of solidification and formation of shrinkage defects in casts with and without chills. It was found that the applied chills influence significantly the hot spots and the remaining part of the cast. Their presence allows to create conditions for solidification of IN-713C nickel superalloy cast without shrinkage defects.
16
Content available remote Technology of laser repair welding of nickel superalloy inner flaps of jet engine
EN
Purpose: of this paper: work out laser welding repair technology of cracked MIG 29 jet engine inner flaps made of cast nickel superalloy ŻS-3DK(ЖС-3ДК, Russian designation). Design/methodology/approach: The study were based on the analysis of laser HPDL powder INCONEL 625 welding of nickel superalloy using wide range of welding parameters to provide highest quality repair welds. Findings: Study of automatic welding technologies GTA, PTA and laser HPDL has shown that just laser welding can provide high quality repair welds. In order to establish the properties of welded joints repair cracks in the inner flap HPDL laser, studied the hardness, mechanical properties and erosive wear resistance. Research limitations/implications: It was found that only laser HPDL welding can provide high quality repair welds. Practical implications: The technology can be applied for repair cracked MIG 29 jet engine inner flaps. Originality/value: Repairing cracked MIG 29 jet engine inner flaps.
17
Content available remote Interactions at the mould - modifying coating - molten nickel alloy interface
EN
The study describes thermal-chemical interactions that take place in the molten nickel alloy-ceramic mould system, where the mould is either coated with a modifying coating ('blue' mould) or is not ('white' mould). The ceramic mould based on zirconium silicate was made by investment process at the WSK Rzeszów Foundry. The main component of the modifying coating was cobalt aluminate CoAl2O4 added in an amount of 10%. Thermodynamic calculations indicated the possibility of chemical reactions taking place between the chemically active nickel alloy constituents (Al, Ti, Hf, Ta and Nb) and the components of a ceramic mould and modifying coating. The result of such interactions is the risk of the formation of cracks on the surface of mould and molten metal penetration into these cracks, combined with the formation of casting defects, like burns-on, pitting, etc., as proved by extensive X-ray microanalysis. Changes of chemical composition in the surface layer of castings were also reported.
EN
The work includes studies to determine the significance of the effect of selected technological parameters of moulding and casting conditions on the macrostructure of IN-713C cast nickel alloy. Two-level, fractional 24-1 experiment was carried out, requiring eight experiments. The evaluation covered the number of grains per 1mm2 of the sample surface, the average grain surface area, and the shape index. Macrostructure of test castings indicates a positive effect of combined surface and bulk inoculation treatment, with the effect of surface inoculation prevailing as regards its importance. Statistically significant effect on the number and surface of grains have in descending order: surface modification, bulk modification and temperature of alloy pouring.
EN
The work includes the results of research on production technology of ceramic filters which, besides the traditional filtering function, play also the role of an inoculant modifying the macrostructure of cast nickel alloys. To play this additional role, filters should demonstrate sufficient compression strength and ensure proper flow rate of liquid alloy. The role of an inoculant is played by cobalt aluminate introduced to the composition of external coating in an amount from 5 to 10 wt.%. The required compression strength (over 1MPa) is provided by the supporting layers, deposited on the preform, which is a polyurethane foam. Based on a two-level fractional experiment 24-1, the significance of an impact of various technological parameters (independent variables) on selected functional parameters of the ready filters was determined. Important effect of the number of the supporting layers and sintering temperature of filters after evaporation of polyurethane foam was stated.
PL
W pracy wytworzono warstwy aluminidkowe na żarowytrzymałym nadstopie niklu Inconel 100 w procesie chemicznego osadzania z fazy gazowej (CVD). Prowadzono procesy: niskoaktywnego osadzania warstwy w temperaturze 1050°C przez 8 h oraz wysokoaktywnego osadzania z fazy gazowej w temperaturze 1020°C przez 8 h. Weryfikację efektów procesu aluminiowania prowadzono w badaniach mikroskopowych (mikrosturktura i głębokość warstwy) oraz mikroananlizy składu chemicznego na przekroju warstwy na podłożu nadstopu Inconel 100. Określono profil nanotwardości na przekroju wytworzonych warstw oraz wykonano badnia przyczepności warstwy do podłoża metodą scratch test.
EN
The aluminide coatings were formed on a heat resisting nickel base superalloy Inconel 100 in a chemical vapour deposition process CVD. It was conducted the following coating deposition processes: the low activity deposition process at the temperature of 1050°C during 8h and the high activity one at the temperature of 1020°C during 8h. The effect of aluminizing process was examined in the microscopic investigations (microstructure and the depth of the coating) and microanalysis of chemical composition on the cross sections of the samples. The depth of the coating zones and the chemical composition of the areas were determined. The nanohardenss measurements on the cross sections of the coatings were carried out. The study of the adhesion of the aluminide coatings on nickel superalloy were performed using a scratch test method.
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