A Review of Constitutive Models and Thermal Properties for Nickel-Based Superalloys Across Machining-Specific Regimes

Abstract

Nickel-based superalloys (Ni-alloys) are widely used in flight-critical aeroengine components because of their excellent material properties at high temperatures such as yield strength, ductility, and creep resistance. However, these desirable high-temperature properties also make Ni-alloys very difficult to machine. This paper provides an overview and benchmarking of various constitutive models to provide the process modeling community with an objective comparison between various calibrated material models, to increase the accuracy of process model predictions for machining of Ni-alloys. Various studies involving the Johnson-Cook model and the calibration of its constants in finite element simulations are discussed. Significant discrepancies exist between researchers' approaches to calibrating constitutive models. Moreover, this paper provides a comprehensive overview of pedigreed physical material properties for a range of Ni-alloys. In this context, the variation of thermal properties and thermally induced stresses over machining temperature regimes are modeled for a variety of Ni-alloys. The chemical compositions and applications for a range of relevant Ni-alloys are also explored. Overall, this manuscript identifies the need for more comprehensive analysis and process-specific characterization of thermomechanical properties for difficult-to-machine Ni-alloys to improve machining performance and aeroengine component quality.

INCONEL® Alloy Machining and Tool Wear Finite Element Analysis Assessment: An Extended Review

“…In order to establish the A, B, C, m, and n constants of the JC model, an initial tensile test is conducted following ASTM A 370-17 [32] guidelines. As shown in Equation (3), the thermal softening effect is deemed negligible for determining C, leading to a rearranged expression. The value of C is derived through a linear regression model using different .…”

“…Renowned for their ability to withstand high temperatures (T) without succumbing to creep, these superalloys proved to be highly attractive and well suited for producing items like jet engines and steam turbines. Following the work of Pedroso et al [2] and Thornton et al [3], it becomes evident that understanding the chip formation mechanism is one of the crucial factors that will lead to a comprehensive understanding of the entire cutting process in conventional manufacturing (CM) [4,5]. When a material exceeds its yield point (σ y , yield stress), it experiences a strain-hardening phenomenon, leading to increased load and energy [6] required for material deformation [7].…”

Simulation of Mechanical Response in Machining of Ti-6Al-4V Based on Finite Element Model and Visco-Plastic Self-Consistent Model

“…The selection of a material constitutive model is essential to improve the accuracy of the simulation results. The Johnson-Cook (JC) constitutive equation is one of the most widely used in FE machining simulations [7,8]. Strain hardening, strain rate hardening, and temperature softening are coupled in the model to analyze material flow stress.…”