1. Abnormal grain coarsening in Inconel 718 aero-engine disc forgings
- Author
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Watson, Richard, Preuss, Michael, and Quinta Da Fonseca, Joao
- Subjects
Grain Growth ,Recrystallization - Abstract
Regions of abnormally coarse grains, have been observed in an industrial forging during a routine metallurgical investigation. These abnormally large grains are not predicted by current recrystallization models and appear seemingly at random. There is currently great uncertainty about the effect on mechanical properties that these microstructures have and consequently the appearance of abnormally coarse grains leads to the scrapping of the forging process and re-tooling of dies, both at great expense. This work aims to improve the understanding of this microstructural phenomenon as well as providing guidance in avoiding and preventing abnormally coarse grains in future industrial forgings. Preliminary experiments showed that abnormal grain coarsening formed during a 980°C solution anneal though it was not clear if this was due to a recrystallization or grain growth process. The initial investigation gave an early indication that grew from newly recrystallized grains, inferred from the stored energy difference between normal and abnormal microstructures assessed using EBSD data. The first set of results also indicated that delta-phase volume fraction or morphology might be to blame as there was clear evidence that the delta-phase was not pinning grain boundaries as precipitates were clearly visible inside grains away from grain boundaries. Further work, utilising isothermal compression, Gleeble compression and isothermal torsion tests, was able to confirm that this phenomenon occurs over a set range of parameters that can be plotted on a processing map. This work has also shown that all observable grain growth comes from new grains, with the as deformed microstructure showing little change as a result of recovery or subsequent grain growth. It is because of this that abnormally coarse grain formation should be considered a recrystallization process with new grains forming through strain induced boundary migration (SIBM). What sets this process apart from normal recrystallization is the presence of 2nd phase particles which hinder grain growth of some newly formed grains leading to an 'abnormal recrystallization' process. This investigation has also shown that abnormal grain coarsening can be prevented by careful manipulation of 2nd phase particle precipitation through prior heat treatment before performing the standard solution anneal, pining the newly formed grains before they can grow. The most promising prior anneal was found to be 1hr at 850°C however the stored energy remains within the microstructure. Further tests are required to assess the impact of this prior anneal on the material performance.
- Published
- 2016