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The main purpose of the present study is to verify the possibility of decarbonizing the surface of heat-resistant ductile iron GJS-XSiMo5-1 to provide a significant difference in carbon content between this material and gray cast iron ENGJL-250. In the future, this will allow to increase the diffusion of elements during the creation of the two-layered material using the casting process with materials in a liquid state and solid state. The above method was assumed to solve the problem of defects on turbocharger’s housing in an economically justified manner which occurred in some high-performance premium applications. Evaluation of decarbonized surface quality was investigated by microstructure observation (light microscopy) and alloy elements diffusion (scanning electron microscopy), and hardness measurement and the element content were checked by spark optical emission spectrometry and glow discharge optical emission spectrometry, respectively.

The macro- and microstructure of nickel superalloys castings, especially thin-walled ones, have a large influence on their mechanical properties. Better understanding of the macro- and microstructure response to casting conditions will enable the optimization of technological and mechanical properties of the alloy. Presented research results refer to different diameter cylindrical specimens of Inconel 713C superalloy cast under various conditions to impose different cooling rates. The function model for correlation between secondary dendrite arm spacing (SDAS) and cooling rate was proposed. Statistical analysis of the influence of the main casting process parameters on the SDAS and cooling rate on grains morphology was performed. It was found that casting diameter had a biggest impact on the SDAS while mold temperature and thermal insulation had less influence on the alloy microstructure. Quantitative microstructural analysis results indicated also the effect of cooling rate on grain size.

In the present study, the dendrites deflection mechanism from the mold walls were subjected to verification regarding its heat-treated turbine rotor blades. The number of macroscopic low-angle boundaries created on the cross-section of the blades’ airfoil near the tip was experimentally determined and compared to the number of low-angle boundaries calculated from a model based on the dendrites deflection mechanism. Based on the Laue patterns and geometrical parameters of airfoils, the number of low-angle boundaries occurring at the upper part of the blades airfoil after heat treatment was calculated. This number for the analyzed group of blades ranged from 5 to 9.

Magnesium and its alloys are widely used in many areas because of their light weight, excellent dimensional stability, and high strength-to-weight ratio. However, the material exhibits poor wear and corrosion resistance, which limits its use. Plasma electrolytic oxidation (PEO) is an effective surface modification method for producing ceramic oxide layers on Mg and their alloys. The influence of the additions of sodium tetrafluoroborate (NaBF4) and sodium fluoride (NaF) into alkaline-silicate electrolyte on the properties of the conversion layers formed in the magnesium AZ91D alloy has been investigated. Surface morphology and chemical composition were determined by scanning electron microscopy (SEM) and X-ray photoelectron spectroscopy (XPS). The anticorrosive properties of the layers were evaluated by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) methods in simulated body fluid (SBF). The presence of NaBF4 or NaF in the electrolyte increases the corrosion resistance of the protective layer. However, the best anticorrosive properties show the layers obtained in the presence of NaBF4. This is probably caused by the incorporation of boron and fluorine in the form of Mg (BF4)2 mainly in the barrier layer.

The areas located near the cooling bores of single-crystalline cored turbine blades made of nickel-based CMSX-4 superalloy were studied. The blades were solidified by the vertical Bridgman technique in the industrial ALD furnace. Longitudinal sections of the blades were studied by Scanning Electron Microscopy, X-ray diffraction topography, X-ray diffraction measurements of the γ′-phase lattice parameter a, and the α angle of the primary crystal orientation. The local changes in α were analyzed in relation to the changes of the dendrite’s growth direction near the cooling bores. It was found that in the area approximately 3 ÷ 4 mm wide around the cooling bores, changes of α and a, both in the blade root and in the airfoil occurred. The local temperature distribution near the cooling bores formed a curved macroscopic solidification front, which caused changes in the chemical composition and, consequently, changes in the a value in a range of 0.002 Å to 0.014 Å. The mechanism of alloying elements segregation by tips of the dendrites on the bent solidification front was proposed. The multi-scale analysis that allows determining a relation between processes proceed both on a millimeter-scale and a micrometric and nanometric scale, was applied in the studies.

In the present study, two commercially available Ni-base superalloys, namely Rene 80 which contains Ti and IN 792 containing Ti and Ta, were investigated during isothermal oxidation at 1,050°C in Ar–20% O2 gas up to 50 h. It was found that IN 792 showed a slightly lower oxidation rate as compared to Rene 80. Also differences in oxide scale microstructures and thicknesses were found. Both alloys formed qualitatively similar oxide scales consisting of outer TiO2 on top of a Cr2O3 scale and internally oxidized Al2O3. The IN 792 formed a thinner oxide scale in general as well as a thinner outer TiO2 scale. Also the depth of the internally oxidized Al2O3 precipitates is smaller in case of IN 792. These findings were correlated with the formation of TiTaO4, which in turn hampered outer Ti and inward oxygen flux.

The roots of cored single-crystalline turbine blades made of a nickel-based CMSX-4 superalloy were studied. The casts were solidified by the vertical Bridgman method in an industrial ALD furnace using the spiral selector and selector continuer situated asymmetrically in the blade root transverse section. Scanning electron microscopy, the Laue diffraction and X-ray diffraction topography were used to visualize the dendrite array and the local crystal misorientation of the roots. It has been stated that heterogeneity of the dendrite array and creation of low-angle boundaries (LABs) are mostly related to the lateral dendrite branching and rapid growth of the secondary and tertiary dendrites near the surface of the continuer&ndash, root connection. These processes have an unsteady character. Additionally, the influence of the mould walls on the dendrite array heterogeneity was studied. The processes of the lateral growth of the secondary dendrites and competitive longitudinal growth of the tertiary dendrites are discussed and a method of reducing the heterogeneity of the root dendrite array is proposed.

One of the important criteria for selection titanium alloys for discs and blades of turbine engine compressor is their fatigue and creep strength at room and elevated temperature. Fatigue and creep properties of two-phase titanium alloys show strong dependence on microstructure, especially morphology of the α and β phases which can be controlled to certain extent by proper selection of hot working and heat treatment conditions. Quantitative description of two-phase titanium alloys behaviour under loading and environmental conditions leading to combined creep and fatigue processes has been always very challenging task due to large number of factors affecting deformation and fracture behaviour of the material. In the course of the research cyclic creep behaviour of Ti-6Al-2Mo-2Cr alloy (VT3-1) was investigated and compared to low-cycle fatigue and static creep properties at the temperature of 450°C. Microstructure of the alloy was varied by means of the heat treatment. Constant load tensile creep tests were carried out. Tension-tension cyclic loading was applied at the constant stress ratio with and without hold time at maximum load. The effect of test parameters on the creep-fatigue life at elevated temperature was estimated. Characteristic features of fracture surfaces were identified by scanning electron microscopy methods.

The variation of the crystal orientation and the dendrite array generated in the root of the single-crystalline (SX) turbine blades made of CMSX-4 superalloy were studied. The blades with an axial orientation of the [001] type were solidified by the industrial Bridgman technique using a spiral selector at a withdrawal rate of 3 mm/min. The analysis of the crystal orientation and dendrite arrangement was carried out using scanning electron microscopy, X-ray diffraction topography, and Laue diffraction. It was found that the lateral growth of such secondary dendrite arms, which are defined as &ldquo, leading&rdquo, and grow in the root at first, is related to the rotation of their crystal lattice, which is the reason for creation of the low-angle boundary (LAB) type defects. The primary crystal orientation of the selector extension (SE) area determines the areas and directions of the lateral growth of the leading arms. Additionally, it was found that in the SE areas of the root, near the connection with the selector, the spatial distribution of the [001]&gamma, &rsquo, crystallographic direction has a complex wave-like character and may be related to the shape of the crystallization front.

Development of mechanical properties of titanium alloys is usually achieved by the control of their microstructure (globular, lamellar, bimodal). Dynamic fragmentation and spheroidization of elongated α phase grains, formed from martensite laths, in the microstructure of Ti-6Al-4V alloy are considered in the paper. The effects of α phase grain spheroidization was evaluated in tensile tests over a temperature range of 800–900°C and strain rate range of 10−3–10−2s−1. Completed spheroidization of elongated α phase grains and subsequent growth of equiaxed grains for all deformation modes were found. A low value of apparent activation energy for deformation was calculated – suggesting grain boundary sliding was the main deformation mechanism. The results showed good correlation with the kinetic rate equation based on the Zener–Hollomon parameter.

This study focuses on the evaluation of the crystal structure perfection in the single crystal made of CMSX-4 nickel superalloy and its effect on creep resistance. Single crystal castings were manufactured by directional solidification process at the withdrawal rate of 1, 3, 5 and 7 mm/min. Light (LM) and electron (SEM, TEM) microscopy, X-ray diffraction and Mossbauer spectroscopy were used for evaluation of the microstructure and crystal structure perfection. Castings were also subjected to creep tests. The best creep resistance was obtained for the casting manufactured at the withdrawal rate of 3 mm/min, characterized by the highest crystal structure perfection compared to the other castings examined.

The process of martensitic α′(α″) phase decomposition in titanium alloys has not been sufficiently characterised in the literature – especially in terms of plastically deformed martensite. ...

Article presents the research results of aircraft compressor blade damage length and its position influence on fatigue strength under high number cycles conditions. The criteria for blade damage detection classification and test research methodology were developed. Designed and tested the instrumentation for compressor blades fatigue tests. Fluorescent method was used to determine the source of fatigue cracking initiation and its propagation direction during fatigue test.

This paper contributes to broadening the knowledge regarding cutting tool wear in the finish turning operations of nickel-chromium-based superalloy Inconel 718. Three cutting tools coated with heat isolating TiAlN/AlTiN layers with different stoichiometry ratios recommended as specially designed cutting tools for aerospace industry applications are tested. The primary comparison of tool wear resistance was based on the wear curves related to the cutting time and the removed material volume. The basic study include the modeling of wear progress and examining tool wear scars based on SME images and EDX analysis. In addition, tool wear progress was recorded along with continuous measurements of cutting forces and determination of relevant amount of the specific cutting energy and the friction coefficient.

Palladium layer (7 μm thick) was deposited on the surface of the Inconel 713 LC, Inconel 625 and CMSX 4 Ni-base superalloys by the electroplating method. Electroplated samples were annealed at 1050 °C for 2 h in the argon atmosphere. The aluminide coatings were deposited by the CVD method. The nonmodified aluminide coating consists of the NiAl phase. Palladium modification let to formation of the (Ni,Pd)Al phase in coatings. The palladium modified as well as nonmodified coatings were oxidized at 1100 °C in the air atmosphere. For both Inconel 713 LC and CMSX 4 superalloys palladium modified coatings show better oxidation resistance than nonmodified ones. Palladium inhibits the outward diffusion of substrate elements (cobalt and chromium) during oxidation of the aluminide coating. Moreover, it stabilizes the β-NiAl phase, keeps the higher content of aluminum in the β-NiAl phase for a long time and thus increases the lifetime of the coated substrate.

The study of thermal resistance (TR) at the casting-mold interface has been performed to describe the solidification process aimed at the improvement of technology and the reduction of defect quantity of investment castings. The analysis of thermal resistance at casting–mold interface between the solidifying IN 713C nickel superalloy plate casting and ceramic shell mold has been presented. The temperature measurements in the plate casting of IN 713C nickel superalloy and the ceramic shell mold were carried out to determine the casting–mold interface heat transfer coefficient (IHTC) with the use of inverse heat conduction method. The calculations were performed using a ProCAST software. It was found that the casting–mold IHTC (7962 Wm−2 K−1) was the highest for the alloy in the liquid state and then it intensively decreased during solidification and cooling followed by its increase close to the end of the solidification process forming another peak on the obtained curve. The formation mechanism of gap between the ceramic mold and Ni based superalloy casting as well as another peak were proposed taking into account the occurrence of mixed oxide scale at the interface. On the basis of numerical simulation, it was found that the IHTC had less influence on cooling rate of casting than the thickness, thermal conductivity and emissivity of the mold for the applied technological parameters of the process.

Inconel 718 is a precipitation hardenable nickel-iron based superalloy. It has exceptionally high strength and ductility compared to other metallic materials. This is due to intense precipitation of the γ’ and γ” strengthening phases in the temperature range 650-850°C. The main purpose of the authors was to analyze the aging process in Inconel 718 obtained in accordance with AMS 5596, and its effect on the mechanical properties. Tensile and hardness tests were used to evaluate the mechanical properties, in the initial aging process and after reheating, as a function of temperature and time respectively in the ranges 650°-900°C and 5-480 min. In addition, to link the mechanical properties with the microstructure transmission microscopy observations were carried out in selected specimens. As a result, factors influencing the microstructure changes at various stages of strengthening were observed. The authors found that the γ’’ phase nucleates mostly homogenously in the temperature range 650-750°C, causing the greatest increase in strength. On the other hand, the γ’ and δ phases are formed heterogeneously at 850°C or after longer annealing in 800°C, which may weaken the material.

The analysis of influence of mould withdrawal rate on the solidification process of CMSX-4 single crystal castings produced by Bridgman method was presented in this paper. The predicted values of temperature gradient, solidification and cooling rate, were determined at the longitudinal section of casting blade withdrawn at rate from 1 to 6mm/min using ProCAST software. It was found that the increase of withdrawal rate of ceramic mould results in the decrease of temperature gradient and the growth of cooling rate, along blade height. Based on results of solidification parameter G/R (temperature gradient/solidification rate), maximum withdrawal rate of ceramic mould (3.5 mm/min), which ensures lower susceptibility to formation process of new grain defects in single crystal, was established. It was proved that these defects can be formed in the bottom part of casting at withdrawal rate of 4 mm/min. The increase of withdrawal rate to 5 and 6 mm/min results in additional growth of susceptibility of defects formation along the whole height of airfoil.

CMSX 4 and Inconel 625 superalloys were coated by platinum layers (3 and 7 μm thick) in the electroplating process. The heat treatment of platinum layers (at 1,050 ˚C for 2 h) was performed to increase platinum adherence to the superalloys substrate. The diffusion zone obtained on CMSX 4 superalloy (3 and 7 μm platinum thick before heat treatment) consisted of two phases: γ-Ni(Al, Cr) and (Al0.25Pt0.75)Ni3. The diffusion zone obtained on Inconel 625 superalloy (3 μm platinum thick before heat treatment) consisted of the α-Pt(Ni, Cr, Al) phase. Moreover, γ-Ni(Cr, Al) phase was identified. The X-ray diffraction (XRD) results revealed the presence of platinum in the diffusion zone of the heat-treated coating (7 μm platinum thick) on Inconel 625 superalloy. The surface roughness parameter Ra of heat-treated coatings increased with the increase of platinum layers thickness. This was due to the unequal mass flow of platinum and nickel.

Results of comparison research of various sensors types used in the fatigue tests for aircraft engine compressor blade vibration amplitude measurement were analysed. Sensors under tests: inductive, capacitive, eddy-current, laser and vibration. Presented were sensors characteristics and their faults. Additional test stand instrumentation was designed and performed, including mounting bracket.

An analysis of the defects in the vicinity of the selector&ndash, root connection plane occurring during the creation of single-crystalline turbine blades made of CMSX-6 Ni-based superalloy was performed. X-ray diffraction topography, scanning electron microscopy, and positron annihilation lifetime spectroscopy were used. Comparing the area of undisturbed axial growth of dendrites to the area of lateral growth concluded that the low-angle boundaries-like (LAB-like) defects were created in the root as a result of unsteady-state lateral growth of some secondary dendrite arms in layers of the root located directly at the selector&ndash, root connection plane. Additional macroscopic low-angle boundaries (LABs) with higher misorientation angles were created as a result of concave curvatures of liquidus isotherm in platform-like regions near selector&ndash, root connections. Two kinds of vacancy-type defects, mono-vacancies and vacancy clusters, were determined in relation to the LABs and LAB-like defects. Only mono-vacancies appeared in the areas of undisturbed axial growth. Reasons for the creation of macroscopic LABs and LAB-like defects, and their relationships with vacancy-type defects were discussed.

The technique of flattening the temperature profile and controlling the formation of both the dendritic microstructure and grain structure in the directional solidification of nickel-based superalloy casting, using the novel inner radiation baffles (IRBs) in the Bridgman process, is presented in this paper. These baffles matched to the shape of mold and were placed horizontally along its height at various distances from the casting base. The plate castings of CMSX-4 superalloy were fabricated without and with the use of IRBs, withdrawing the mold at the rate of 6 mm/min from the heating to the cooling area of the industrial Bridgman furnace. Thermal analysis of the directional solidification of castings was carried out using the ProCAST software for a process where the various designs of the radiation baffle were applied. The results of the solidification conditions, the shape of liquidus and solidus isotherms, and grain structure obtained for the IRBs were compared with those reached for the standard ring-shaped (AERB) or perfectly adjusted (PARB) radiation baffles. The use of IRB resulted in flattening of the temperature distribution and decrease of the curvature of liquidus and solidus isotherms, as well as an increase of temperature gradient and cooling rate, compared with the process where AERB was only used. Consequently, primary dendrite arm spacing (PDAS) reached similar values across the width of casting and equaled to approximately 370 &mu, m, reducing its average value by 26%, compared with the standard process. The change in predicted axial temperature gradient in casting was not found when thermophysical properties of molybdenum IRBs were used. The increase in graphite IRBs number in mold from seven to 14 caused the reduction of inhomogeneity of axial temperature gradient along the casting height.

In this paper authors overviewed the most important stages of ceramics production process which give significant influence on final properties of product. Often density and porosity on the all producing stages determines exploitation ceramics properties. A calculation method for fractions ratio selection which provides optimal density is suggested here. Also, density changes during operations of grinding, forming, thermal treatment and sintering a row of specimens are researched and analysed. The data received allow to predict semi products size behaviour while producing and get definite final part with dimension required.

The method of temperature measurement in directionally solidified (DS) Ni-based CMSX-4 superalloy castings manufactured using withdrawal rates of 3 and 5 mm/min in the Bridgman furnace with graphite heaters, was successfully improved. The numerical simulation of directional solidification process was performed with the use of ProCAST software, for withdrawal rates of 1, 3 and 5 mm/min in order to predict cooling rate, axial and transverse temperature gradients, solidification rate, height of mushy zone, shape of liquidus isotherm and its location relative to thermal baffle along the casting height. The critical distance from chill plate, above which of the steady-state solidification process starts, was established. The liquidus isotherm attained the concave, convex or flat shape, in dependence on withdrawal rate of casting and the distance from chill plate. The relationship between the shape of liquidus isotherm and grain structure was found for castings withdrawn at 1 and 5 mm/min. Grains grew in the direction of the rod axis and that of casting surface for the concave and convex isotherm shape, respectively. The flat shape of liquidus isotherm induced grain growth in the direction which was the most parallel to axis of casting.

The influence of internal thermal baffle between casting and central rod of the ceramic mould on the shape of liquidus isotherm was studied. Convex or nearly flat shape of solidification front was obtained after selection of suitable location of internal thermal baffle relative to the platform, based on measured and predicted temperature distribution. The results were compared with those acquired for castings manufactured with the use of standard mould. Application of internal thermal baffle brought about decrease of solidification front curvature, as well as transverse temperature gradient Gx = 0.2 °C/mm and maximum undercooling value ΔTm = 16.5 °C, which succeeded in proper growth of dendrites compared with Gx = 2.8 °C/mm and ΔTm = 36.5 °C in the mould without internal baffle. The convex shape of liquidus isotherm induced directional course of solidification process in the area, where casting cross-section changed significantly its dimensions, but it also led to excessive growth of shrinkage porosity on the platform surface. The increase of the distance between the platform and thermal baffle resulted in significant reduction of amount and size of pores along the length of the internal zone of platform.

Creep and fatigue properties of two-phase titanium alloys show strong dependence on microstructure, especially morphology of the α and β phases which can be controlled to certain extent by proper selection of hot working and heat treatment conditions. In the paper the creep behaviour of Ti-6Al-2Mo-2Cr alloy (VT3-1) at elevated temperature was modelled. Finite element analyses of primary creep stage were carried out taking into account some microstructural features of the two-phase alloy that were included in the physical model and different properties of α and β phases. In order to verify results of calculations distinct types of microstructure were developed in the alloy by heat treatment and creep tests were carried out at elevated temperature (450°C) at various stress levels. Based on the FEM simulations the effect of changes of some microstructure features on primary creep strain development was estimated.

The generalized Darken method was applied to simulate the diffusion between γ-Ni| γ’-Ni3Al and γ’-Ni3Al|β-NiAl interfaces. The results of calculations were compared with the experimental concentration’s profiles of nickel, aluminum and hafnium in aluminide and hafnium doped aluminide coatings deposited by the CVD and PVD methods on pure nickel. The method deals with the Wagner’s integral diffusion coefficients and thermodynamic data - activities of components. The experimental results agree with the simulated ones.

The influence of the Na2MoO4 initial concentration on the corrosion rate of aluminium in the H3PO4 solution (0.5, 1, 2 M) between 290 and 323 K was studied using a gasometric technique. Inhibition efficiency was calculated. Depending on the initial concentration of Na2MoO4 the inhibition mechanism was either the adsorption of the inhibitor onto the surface of metal or the adsorption together with the formation of the conversion coatings. The solutions of 1 M H3PO4, 50 mM Na2MoO4 may be applied to determine the mass per unit area and thickness of anodic coatings.