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Experimental investigation on surface integrity and fatigue of nickel-based single-crystal superalloy DD6 during grinding-shot peening composite manufacturing

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Abstract

Surface integrity is an important factor affecting service performance of parts. Favorable machined surface state can greatly improve fatigue life of parts. Multi-process composite manufacturing is a common processing method in high-end manufacturing. In this study, the surface integrity and fatigue properties of nickel-based single-crystal superalloy DD6 after grinding-shot peening composite manufacturing were investigated. The influence of grinding and shot peening process parameters on the surface integrity of DD6 was introduced in detail and mainly analyzed the changes of surface topography and roughness, microstructure, microhardness, residual stress, fatigue life, and fracture morphology. The results show that compared with grinding, grinding-shot peening composite manufacturing increases the surface roughness with the increase of process strength. Grinding-shot peening composite processing will aggravate the shear fracture degree of γ phase and γ′ phase, forming a deeper surface plastic deformation layer; the surface microhardness reaches 645 HV; the hardened layer depth reaches 110 μm; and the residual compressive stress introduced on the surface improves with the increase of process strength. The fatigue life of composite manufacturing at 760 °C is 2.06 times longer than that of grinding. The fatigue fracture surface cracks along the {111} crystal plane. The grinding-shot peening composite manufacturing can slow down the crack propagation to the surface and prolong the fatigue life.

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The raw/processed data required to reproduce these findings cannot be shared at this time, as the data also forms part of an ongoing study.

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Acknowledgements

The authors appreciated the help of the surface integrity test equipment provided by the Analytical & Testing Center in Northwestern Polytechnical University for this study.

Funding

This work was supported by the National Science and Technology Major Project [grant numbers 2017-VII-0002–0095]; the National Natural Science Foundation of China [grant number 92160301]; the National Natural Science Foundation of China [grant number 91860206]; and Shaanxi Provincial Science and Technology Innovation Team Plan [grant number 2021ZDLGY10-06].

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, School of Mechanical Engineering, Northwestern Polytechnical University, Box 552, Xi’an, 710072, Shaanxi, People’s Republic of China

    Changfeng Yao, Jianxin Luo, Liang Tan, Minchao Cui, Yunqi Sun, Xuhang Gao & Ya Zhang

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, People’s Republic of China

    Changfeng Yao, Jianxin Luo, Liang Tan, Minchao Cui, Yunqi Sun, Xuhang Gao & Ya Zhang

Authors
  1. Changfeng Yao
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  2. Jianxin Luo
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  3. Liang Tan
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  4. Minchao Cui
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Contributions

Changfeng Yao contributed to the conception of this study. Jianxin Luo has made outstanding contributions in the experiments and data analysis of grinding-shot peening composite manufacturing. Liang Tan, Minchao Cui, and Yunqi Sun give some suggestions on the content arrangement of this paper. Xuhang Gao and Ya Zhang have done some work in surface integrity tests.

Corresponding author

Correspondence to Changfeng Yao.

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This research mainly focuses on the field of machining. No animal or human biological experiments were involved. So the ethical approval was not required for this research.

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This manuscript is approved by all the authors for publication. I would like to declare on behalf of my co-authors that the work described was original research that has not been published previously and not under consideration for publication elsewhere, in whole or in part.

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Yao, C., Luo, J., Tan, L. et al. Experimental investigation on surface integrity and fatigue of nickel-based single-crystal superalloy DD6 during grinding-shot peening composite manufacturing. Int J Adv Manuf Technol 125, 3449–3463 (2023). https://doi.org/10.1007/s00170-023-10860-0

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