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1

Evolution of δ phase precipitates in Inconel 625 superalloy additively manufactured by laser powder bed fusion and its modeling with fuzzy logic

Staroń Sylwia, Macioł Piotr, Dubiel Beata, Gola Kewin, Falkus Jan

Archives of Civil and Mechanical Engineering

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2023

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Vol. 23, no. 2

art. no. e86, 2023

EN

Experimental and modeling studies of the evolution of plate-like δ phase precipitates in Inconel 625 superalloy additively manufactured by the laser powder bed fusion process are performed. The maximum Feret diameter and the number of particles per unit area are used as parameters describing the size and distribution of the δ phase precipitates. On the basis of microstructural analysis and quantitative image analysis, the effect of time and temperature on the development of δ phase precipitates is determined. The distinct differences in the intensity of precipitation, growth, and coarsening of the δ phase precipitates during annealing at temperatures of 700 and 800 °C up to 2000 h are shown. The experimental results are compared with computational data obtained by thermodynamic modeling. Using the experimentally determined parameters of the δ phase precipitates in different variants of annealing, a fuzzy logic-based phase distribution model is designed. Since the quantity of available data was too small to train a model with the machine learning approach, expert knowledge is used to design the rules, while numerical data are used for its validation. Designed rules, as well as reasoning methodology are described. The proposed model is validated by comparing it with the experimental results. It can be used to predict the size and number density of the δ phase precipitates in the additively manufactured Inconel 625, subjected to long-term annealing at temperatures of 700-800 °C. Due to limited experimental data, the quality of assurance is not perfect, but warrants preliminary research.

2

Structure and properties of laser-cladded Inconel 625-based in situ composite coatings on S355JR substrate modified with Ti and C powders

Poloczek Tomasz, Lont Aleksandra, Górka Jacek

Materials Science Poland

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2022

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Vol. 40, No. 4

14--27

EN

This article presents the research results on the production of laser-cladded Inconel-625 in situ composite coatings on the S355JR substrate by addition of titanium and graphite powders to pure Inconel 625 alloy powder mixture for increased hardness and erosive wear resistance of the coatings. The research featured in the article includes penetrant testing, macro-, and microscopic observations of produced coatings, phase and chemical composition analysis, hardness and solid particle erosion tests. The results showed that the addition of titanium and graphite powders resulted in the composite microstructure formation by precipitation of Ti, Nb, Mo, and C-rich blocky and eutectic particles during crystallization. The conducted tests revealed that the microstructure change resulted in an increase in hardness and erosive wear resistance by 27% and 30%, respectively.

3

Microstructure and Properties of Dissimilar Joints of AISI 430 Steel with Inconel 625 Obtained by Electron Beam Welding

Dziekońska Małgorzata, Jonda Ewa, Sroka Marek, Węglowski Marek Stanisław, Jung Tymoteusz

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no 4

232--242

EN

Electron Beam Welding (EBM) is a high-energy density fusion process where joint is bombarded to be welded with strongly focused beam of electrons. This method is often used for advanced materials and complex, critical parts, like turbine rotors, but it can also be used for many simpler processes involving large production runs. It is very suitable for butt welding materials of different thicknesses. The aim of this work was to study the microstructure, hardness, and electrochemical corrosion behavior between the dissimilar welds were investigated. Electron Beam Welding of dissimilar steel alloys Inconel 625 and AISI 430 was studied. In welding process there was used only welded materials without filling material. Results showed the microstructure of the weld solidified in dendritic morphology. The microstructure of fusion zone showed that dendrites grew in different directions for each grain. The dendrites and columnar grains are mainly exposed to the fusion boundary with some equiaxed grains. The hardness of the overall joint was non-uniform. The highest hardness of the HAZ/Inconel 625 (the heat-affected zone) was 258 HV, and the lowest weld zone hardness was 178 HV. The decrease in weld hardness may be due to the linear welding energy, which led to grain growth and excessive cooling. HAZ/AISI 430 steel has the lowest current density and the highest corrosion potential. Steel has a more negative corrosion potential and a lower corrosion current density than joints, likely due to higher levels of chromium. In this study, a metallographic investigation of the joints revealed no defects such as microcracks or pores. The melting temperatures of the two materials were quite different, but with the help of gravity, stainless steel acts as a permanent joint, like a rivet.

4

Microstructure and Properties of Laser Additive Deposited of Nickel Base Super Alloy Inconel 625

Danielewski H., Antoszewski B.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 3

53--59

EN

Article presents results of laser overlaying welding of metal powder Inconel 625. Laser metal deposition by laser engineered net shaping (LENS) is modern manufacturing process for low scale production series. High alloy materials such as Inconel 625 nickel based super alloy have high thermal resistant and good mechanical properties, nevertheless it's hard to machining. Plastic forming of high alloy materials such as Inconel 625 are difficult. Due to high strength characteristic performing components made from Inconel alloy are complex, selective melting of metallic powder using laser beam are alternative method for Inconel tooling. Paper present research of additive deposition of spatial structure made from Inconel 625 metallic powder with CO2 laser and integrated powder feeder. Microstructure analysis as well as strength characteristic in normal condition and at elevated temperature was performed. Possibility of using LENS technology for manufacturing components dedicated for work in high temperature conditions are presented.

5

Poprawa porowatości przedmiotów z Inconelu 625 wytwarzanych metodą druku 3D

Jemielniak Krzysztof

Mechanik

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2019

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R. 92, nr 8-9

514

PL

Druk 3D metodą bezpośredniej depozycji energii – DED (direct energy deposition) – wiąże się ze stosowaniem dużej ilości energii cieplnej, która generuje gradient temperatury w wytwarzanym wyrobie. Zwykle prowadzi to do niespodziewanej anizotropii i osłabienia materiału przez resztkową porowatość. Te problemy można rozwiązać dzięki dodatkowej procedurze przetapiania, zapewniającej kontrolowaną orientację kryształów i redukcję porowatości.

6

Napawanie laserowe warstw kompozytowych na osnowie stopu Inconel 625

Janicki D., Górka J., Kotarska A.

Welding Technology Review

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2018

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R. 90, nr 9

6--12

PL

Artykuł prezentuje wyniki badań procesu napawania laserem diodowym warstw wierzchnich kompozytowych na osnowie stopu niklu Inconel 625 wzmacnianych cząstkami WC oraz Cr3C2. Określono wpływ energii linowej napawania oraz morfologii cząstek fazy umacniającej (FU) na stopień jej rozpuszczenia w osnowie warstwy. Ponadto, określono wpływ morfologii cząstek FU na odporność erozyjną warstw.

EN

Inconel 625-based composite coatings reinforced by WC and Cr3C2 particles have been produced via a diode laser cladding process. The effect of heat input level and morphology of the reinforcing particles on the degree of their dissolution has been established. Additionally, the influence of the morphology of the reinforcing particles on the erosive wear behaviour of the coatings was studied.

7

The Structure and Coefficient of Friction of Welded Nickel Alloys Inconel 625 and Inconel 718

Strzelczak K., Dudek A.

Tribologia

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2018

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nr 5

109--115

EN

In this study, the coefficients of friction for three series of welded nickel alloy joints, subjected to different heat treatments (lack of heat treatment, solution heat treatment, precipitation hardening), were determined. Heat treatment of the prepared samples was aimed at eliminating the structural and stress gradient, because the electron beam welding technique is dedicated for constructions with very high quality and strength requirements. Given the nature of the electron beam process, the authors are aware that the obtained weld’s structures are characterized by different properties from parent materials, and also from structures melted under equilibrium conditions. The scientific aim of the presented work is to determine the influence of heat treatment on the microstructure, mechanical properties, and performance of dissimilar joints of nickel alloys Inconel 625 and Inconel 718. In order to determine the coefficient of friction for samples, the scratch test method was used. As a result of the research, it was proved that subjecting the welds to the precipitation hardening has a significant effect on abrasion resistance.

PL

Wyznaczono współczynniki tarcia dla trzech serii próbek poddanych odmiennym procesom obróbki cieplnej (brak obróbki cieplnej, przesycanie, utwardzanie wydzieleniowe). Obróbka cieplna przygotowanych próbek miała na celu zlikwidowanie gradientu strukturalnego i naprężeniowego, ponieważ spawanie wiązką elektronów dedykowane jest dla urządzeń o bardzo wysokich wymaganiach jakościowych i wytrzymałościowych. Biorąc pod uwagę charakter procesu spawania wiązką, autorzy mają świadomość, iż uzyskane struktury będą cechowały się zdecydowanie odmiennymi własnościami od materiału rodzimego, ale również i od struktur przetopionych w warunkach bliskich warunkom równowagowym. Celem naukowym pracy jest określenie wpływu obróbki cieplnej na mikrostrukturę, własności mechaniczne i użytkowe różnoimiennych połączeń stopów niklu Inconel 625 oraz Inconel 718. W celu wyznaczenia współczynników tarcia dla próbek zastosowano metodę zarysowania scratch test. W wyniku przeprowadzonych badań dowiedziono, że poddanie spoin procesowi utwardzania wydzieleniowego ma znaczący wpływ na odporność na ścieranie.

8

Badania złącza doczołowego blachy stalowej platerowanej wybuchowo stopem niklu Inconel 625

Szmul M., Pocica A., Szulc Z.

Przegląd Spawalnictwa

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2018

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R. 90, nr 4

43--46

PL

W artykule przedstawiono porównanie dwóch technologii wykonania złącza doczołowego stali P355NH platerowanej wybuchowo stopem Inconel 625. Przedstawiono wpływ zastosowania prądu pulsującego na skład chemiczny ściegów wykonanych metodą 131. Opracowana technologia spawania zapewniła uzyskanie składu chemicznego zgodnie z wymaganiami norm ASME SECTION II, PART A oraz PN-EN 10095:2002.

EN

The article presents a comparison of two welding technologies of butt joints of explosively cladded P355NH - Inconel 625 plate. The influence of applying pulsing current on the chemical composition of stitches made by method 131 is presented. The applied welding technology ensure the chemical composition in accordance with the requirements of ASME SECTION II, PART A and PN-EN 10095:2002.

9

Annealing effect on microstructure and chemical composition of Inconel 625 alloy

Petrzak P., Kowalski K., Rozmus-Górnikowska M., Dębowska A., Jędrusik M., Koclęga D.

Metallurgy and Foundry Engineering

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2018

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Vol. 44, no. 2

73--80

EN

Our research focused on Inconel 625 weld overlays on 16Mo3 steel boiler pipes. The investigation focused on the characterization of changes in the microstructure and chemical composition after annealing. The annealing was performed for ten hours at temperatures from 600 to 1000°C. Changes in the microstructure were observed with a scanning and transmission electron microscope (SEM and TEM). The investigation was supplemented by hardness measurements.

PL

Badania przeprowadzono na napoinach ze stopu Inconel 625 na stali kotłowej 16Mo3. Skoncentrowano się na charakterystyce mikrostruktury i składu chemicznego zmian po wyżarzaniu. Obróbkę cieplną przeprowadzono w temperaturze od 600 do 1000°C przez 10 godzin. Zmiany mikrostruktury obserwowano przy użyciu skaningowej i transmisyjnej mikroskopii elektronowej (SEM i TEM). Badania zostały uzupełnione o pomiary twardości.

10

Laser treatment with 625 Inconel powder of hot work tool steel using fibre laser YLS-4000

Dobrzański L. A., Jonda E., Pakieła W., Dziekońska M.

Journal of Achievements in Materials and Manufacturing Engineering

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2018

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Vol. 91, nr 2

60--67

EN

Purpose: The purpose of this investigation was to determine the changes in the surface layer (Inconel 625), obtained during the laser treatment of tool-steel alloy for hot work by the use high-power fibre laser. Design/methodology/approach: Observations of the layer structure, HAZ, and substrate material were made using light and scanning microscopy. The composition of elements and a detailed analysis of the chemical composition in micro-areas was made using the EDS X-ray detector. The thickness of the resulting welds, heat affected zone (HAZ) and the contribution of the base material in the layers was determined. Findings: As a result of laser cladding, using Inconel 625 powder, in the weld overlay microstructure characteristic zones are formed: at the penetration boundary, in the middle of weld overlay and in its top layer. It was found that the height of weld overlay, depth of penetration, width of weld overlay and depth of the heat affected zone grows together with the increasing laser power. Practical implications: Laser cladding is one of the most modern repair processes for eliminating losses, voids, porosity, and cracks on the surface of various metals, including tool alloys for hot work. Laser techniques allow to make layers of materials on the repaired surface, that can significantly differ in chemical composition from the based material (substrate material) or are the same. Originality/value: A significant, dynamic development in materials engineering as well as welding technologies provides the possibility to reduce the cost of production and operation of machinery and equipment, among others by designing parts from materials with special properties (both mechanical and tribological) and the possibility of regeneration of each consumed element with one of the selected welding technologies.

11

Microstructure, Chemical and Phase Composition of Clad Layers of Inconel 625 and Inconel 686

Solecka M., Kopia A., Petrzak P., Radziszewska A.

Archives of Metallurgy and Materials

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2018

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Vol. 63, iss. 1

513--518

EN

The article presents the investigation results of microstructural, chemical composition changes after clad layers of Inconel 625 and Inconel 686 alloys weld overlaid on boiler tubes. The boiler tubes made of 16Mo3 steel were cladded in the Boiler Factory SEFAKO S.A. using CMT technique. The microstructure and chemical composition of coatings were analysed using light microscopy, scanning and transmission electron microscopy. The value of the partition coefficient k was determined for Inconel 625 and Inconel 686 clad layers. The value was calculated by dividing the average content (% wt.) of Ni, Cr, Mo, Fe, Nb and W.

12

Effect of the cutting tool geometry on the tool wear resistance when machining Inconel 625

Zlámal Tomáš, Hajnyš Jiří, Petrů Jana, Mrkvica Ivan

Advances in Science and Technology. Research Journal

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2018

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Vol. 12, no 1

236--243

EN

The paper deals with the design of a suitable cutting geometry of a tool for the machining of the Inconel 625 nickel alloy. This alloy is among the hard-to-machine refractory alloys that cause very rapid wear on cutting tools. Therefore, SNMG and RCMT indexable cutting insert were used to machine the alloy. The selected insert geometry should prevent notch wear and extend tool life. The alloy was machined under predetermined cutting conditions. The angle of the main edge and thus the size and nature of the wear changed with the depth of the material layer being cut. The criterion for determining a more suitable cutting geometry was the tool’s durability and the roughness of the machined surface.

13

Mikrostruktura i skład chemiczny powłok ze stopów Inconel 625 i 686 napawanych metodą CMT na stali 16Mo3

Petrzak P., Kowalski K., Rozmus-Górnikowska M.

Przegląd Spawalnictwa

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2017

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R. 89, nr 6

24--29

PL

W artykule zaprezentowano wyniki badań mikrostruktury, składu chemicznego i właściwości mechanicznych napoin ze stopów Inconel 625 i 686 (NiCr22Mo9Nb i NiCr21Mo16W) nanoszonych na rury ze stali 16Mo3. Napoiny wykonano metodą Cold Metal Transfer (CMT). Badania przeprowadzono z wykorzystaniem mikroskopii świetlnej (LM), skaningowej (SEM) i transmisyjnej (TEM). Próbki poddano jakościowej i ilościowej analizie składu chemicznego techniką EDS. Dokonano oceny mikrosegregacji pierwiastków stopowych następującej podczas krzepnięcia napoiny. Dodatkowo wykonano pomiary twardości metodą Vickersa.

EN

The paper presents results of the investigation of the microstructure, chemical composition and mechanical properties of Inconel 625 and 686 (NiCr22Mo9Nb and NiCr21Mo16W) weld overlays deposited on 16Mo3 steel. The weld overlays were made by Cold Metal Transfer (CMT) technique. Investigation were carried out using light microscopy (LM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The samples were subjected to quantitative and qualitative chemical composition analysis with use of EDS. An evaluation of microsegregation of alloy elements during solidification of the weld overlay was performed. The investigation was supplemented by the hardness measurements (Vickers method).

14

Determinants of the quality of brazed joints of nickel-based superalloys

Strzelczak K., Lisiecka B.

Production Engineering Archives

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2017

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Vol. 16

12--15

EN

In the aerospace industry, passenger safety depends on proper quality control at each production stage. The main responsibility for the correct operation of the aircraft lies within a gas turbine. A proper and rigorous selection of the gas turbine construction material is required, and in a further step, the method of joining the construction parts. Nickel superalloys due to the high heat resistance, strength and creep resistance at high temperatures, toughness and corrosion resistance, are very often used for the construction of a gas turbine engine. In the next step, the selection of joining method is necessary. This method must be able to achieve high-quality connections, resistant to work at high temperatures and corrosive environments. The most effective bonding method that meets the above conditions is brazing. In this study non-destructive (visual) test and destructive (metallographic) test of brazed joint of Inconel 718 and Inconel 625 were conducted.

15

TEM Microstructure and Chemical Composition of Transition Zone between Steel Tube and an Inconel 625 Weld Overlay Coating Produced by CMT Method

Rozmus-Górnikowska M., Blicharski M.

Archives of Metallurgy and Materials

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2017

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Vol. 62, iss. 2A

787--793

EN

The aim of this work was to investigate the microstructure and chemical composition of the transition zone between 16Mo3 steel and Inconel 625 weld overlay coating produced by the Cold Metal Transfer (CMT) method. Investigations were primarily carried out through transmission electron microscopy (TEM) on thin foils prepared by FIB (Focus Ion Beam). The chemical analysis demonstrated that the amount of certain elements (Fe, Ni, Cr, Mo, Nb) in the transition zone between the base material and the weld overlay changes quickly, from the composition of the steel to the composition of the composite zone. STEM and TEM investigations revealed that two areas are clearly visible in the transition zone. In the narrow band close to the fusion boundary where plates are clearly visible and the Ms temperature is higher than room temperature, electron diffraction analyses show reflections of martensite and austenite. Moreover, the crystallographic relations between martensite and austenite can be described by the Kurdjumov-Sachs (K-S) relationship {110}α’ || {111}γ <111>α’ || <110>y ). The microstructure of the part of the transition zone with an Ms temperature lower than room temperature as well as that of the composite zone is austenite. The investigations proved that the width of the martensitic area can be significantly limited by using the CMT technique for weld overlaying.

16

Studies on the Corrosion Resistance of Laser-Welded Inconel 600 and Inconel 625 Nickel-Based Superalloys

Łyczkowska K., Michalska J.

Archives of Metallurgy and Materials

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2017

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Vol. 62, iss. 2A

653--656

EN

The paper presents the results of the electrochemical corrosion tests of Inconel 600 and Inconel 625 laser-welded superalloys. The studies were conducted in order to assess the resistance to general and pitting corrosion in 3.5% NaCl solution. It was found that Inconel 600 possesses good corrosion resistance, however Inconel 625 is characterized by a greater resistance to general and also to pitting corrosion of the weld as well as the base metal.

17

Research on Liquid Forming Process of Nickel Superalloys Thin Sheet Metals

Hyrcza-Michalska M.

Archives of Metallurgy and Materials

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2017

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Vol. 62, iss. 4

2355--2358

EN

The paper presents the study of drawability of thin sheet metals made of a nickel superalloy Inconel type. The manufacturing process of axisymmetric cup – cone and a closed section profile in the form of a circular tube were designed and analyzed. In both cases, working fluid-oil was used in place of the rigid tools. The process of forming liquid is currently the only alternative method for obtaining complex shapes, coatings, and especially if we do it with high-strength materials. In the case of nickel superalloys the search for efficient methods to manufacture of the shaped shell is one of the most considerable problems in aircraft industry [1-5]. However, the automotive industries have the same problem with so-called advanced high-strength steels (AHSS). Due to this, both industrial problems have been examined and the emphasis have been put on the process of liquid forming (hydroforming). The study includes physical tests and the corresponding numerical simulations performed, using the software Eta/Dynaform 5.9. Numerical analysis of the qualitative and quantitative forecasting enables the formability of materials with complex and unusual characteristics of the mechanical properties and forming technology. It has been found that only the computer aided design based on physical and numerical modeling, makes efficient plastic processing possible using a method of hydroforming. Drawability evaluation based on the determination of the mechanical properties of complex characteristics is an indispensable element of this design in the best practice of industrial manufacturing products made of thin sheet metals.

18

Microstructural and Mechanical Study of Inconel 625 - Tungsten Carbide Composite Coatings Obtained by Powder Laser Cladding

Huebner J., Rutkowski P., Kata D., Kusiński J.

Archives of Metallurgy and Materials

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2017

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Vol. 62, iss. 2A

531--538

EN

This study focuses on the investigation of fine (~0.54 μm) tungsten carbide particles effect on structural and mechanical properties of laser cladded Inconel 625-WC composite. Three powder mixtures with different Inconel 625 – WC weight ratio (10, 20 and 30 weight % of WC) were prepared. Coatings were made using following process parameters: laser beam diameter ø ≈ 500 μm, powder feeder rotation speed – 7 m/min, scanning velocity – 10 m/min, laser power – 220 W changed to 320 W, distance between tracks – 1 mm changed to 0.8 mm. Microstructure and hardness were investigated. Coatings produced by laser cladding were crack and pore free, chemically and structurally homogenous. High cooling rate during cladding process resulted in fine microstructure of material. Hardness improved with addition of WC from 396.3 ±10.5 HV for pure Inconel 625, to 469.9 ±24.9 HV for 30 weight % of WC. Tungsten carbide dissolved in Inconel 625 which allowed formation of intergranular eutectic that contains TCP phases.

19

An Analysis of Rheological Properties of Inconel 625 Superalloy Feedstocks Formulated with Backbone Binder Polypropylene System for Powder Injection Molding

Gökmen U., Türker M.

Archives of Metallurgy and Materials

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2017

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Vol. 62, iss. 4

1937--1944

EN

Binder formula is one of the most significant factors which has a considerable influence on powder injection molding (PIM) processes. In the study, rheological behaviors and properties of different binder systems containing PIM feedstocks, Inconel 625 powder commonly used in space industry, were investigated. The feedstocks were prepared 59%-69% (volume) powder loading ratios with three diversified binder systems by use of Polypropylene as backbone binder. The average particle size of the Inconel 625 powder used was 12.86 microns. Components used in the binder were mixed for 30 minutes as dry in three dimensional mixing to prepare binder systems. Rheological features of the feedstock were characterized by using a capillary rheometer. Viscosities of the feedstocks were calculated within the range of 37.996-1900 Pa.s based on the shear rate, shear stress, binder formula and temperature. “n” parameters for PIM feedstocks were determined to be less than 1. Influences of temperature on the viscosities of the feedstocks were also studied and “Ea” under various shear stresses were determined within the range of 24.41-70.89 kJ/mol.

20

Effect of the cutting tool geometry on the tool wear resistance when machining Inconel 625

Zlámal T., Hajnyš J., Petrů J., Mrkvica I.

Advances in Science and Technology. Research Journal

|

2017

|

Vol. 11, no 4

286--293

EN

The paper deals with the design of a suitable cutting geometry of a tool for the machining of the Inconel 625 nickel alloy. This alloy is among the hard-to-machine refractory alloys that cause very rapid wear on cutting tools. Therefore, SNMG and RCMT indexable cutting insert were used to machine the alloy. The selected insert geometry should prevent notch wear and extend tool life. The alloy was machined under predetermined cutting conditions. The angle of the main edge and thus the size and nature of the wear changed with the depth of the material layer being cut. The criterion for determining a more suitable cutting geometry was the tool’s durability and the roughness of the machined surface.