Fretting wear behavior of Inconel 718 alloy manufactured by DED and treated by UNSM

Abstract

Alloy 718 is commonly used in the maritime and aerospace industries due to its strength and durability, particularly in engine rotating components such as disks, fan blades, and high-pressure compressors. As a new type of 3D printing technology, directed energy deposition (DED) can employ lasers to melt metal powders or wires to fabricate arbitrary-shaped workpieces directly from customized data, thereby making machining more synergistic and intuitive. However, the surface properties of the DED-printed alloy 718 samples, such as surface roughness and wear resistance, are typically subpar. By introducing severe plastic deformation to the near-surface, ultrasonic nanocrystal surface modification (UNSM) can be used as a post-processing method and results in altered properties. The uniaxial tensile test reveals that the UNSM-treated alloy 718 exhibits a higher mechanical property. Moreover, using a fretting test rig in accordance with the cylinder-on-plane agreement, a higher wear resistance for UNSM-treated alloy 718 is observed. This study employs the finite element method to fully comprehend the effect of UNSM on wear performance. The fretting wear process of Inconel 718 alloy is established using an energy-based finite element model. Considering the severe practical scenarios, the Johnson–Cook constitutive model is implemented, with the linear isotropic hardening model capturing the plastic behavior. In comparison to experimental measurements, the finite element results demonstrate unprecedented wear loss consistency with an error of less than 2%. Therefore, we conclude that the finite element model built in this study exhibits a high accuracy and can be used to analyze the effect of UNSM on fretting wear behavior. According to finite element analysis, as the normal load increases, the improvement in wear resistance induced by UNSM decreases. Given that the finite element model is based on the energy method, the effects of coefficient of friction (COF) and wear coefficient modified by UNSM are investigated separately. According to the findings, the UNSM-modified COF and wear coefficient play a significant role in determining the wear characteristics. Due to the removal of a substantial amount of material from the central area of the alloy 718 surface by wear, it is also possible to observe that severe plastic strains are primarily concentrated at the edges of the wear scars.

Application and Prospect of Wear Simulation Based on ABAQUS: A Review

“…There is no one explicit approach to obtain the value of k D during the wear process [14,20]. In wear simulation, the wear coefficient is always considered as a constant [8] and obtained from experimental results. The equation is given by:…”

“…Despite this drawback, the depth of wear and the changing trend of the wear profile are generally consistent with the experimental results. The energy dissipation model is considered superior to the Archard wear equation [8,88]. Li et al [97] presented a method based on the energy law to study the fretting wear of the double rough surfaces.…”

“…The research demonstrated that the combined effect of the normal load and amplitude had an impact on the contact pressure and shear stress, which in turn influenced the kinetic behavior, wear behavior, and evolution of worn surfaces. Li et al [8] studied the fretting wear performance of the Inconel 718 alloy-based energy wear approach. In addition, Bastola et al [14] showed that there is no FE method for describing the wear of two 3D bodies simultaneously using adaptive mesh.…”