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Chen, Zhe
Publications (10 of 13) Show all publications
Chen, Z., Peng, R. L., Zhou, J., M'Saoubi, R., Gustafsson, D. & Moverare, J. (2019). Effect of Machining Parameters on Cutting Force and Surface Integrity when High-Speed Turning AD730™ with PCBN Tools. The International Journal of Advanced Manufacturing Technology, 100(9-12), 2601-2615
Open this publication in new window or tab >>Effect of Machining Parameters on Cutting Force and Surface Integrity when High-Speed Turning AD730™ with PCBN Tools
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2019 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 100, no 9-12, p. 2601-2615Article in journal (Refereed) Published
Abstract [en]

The novel wrought nickel-based superalloy, AD 730™, is a good candidate material for turbine disc applications at high temperatures beyond 650 °C. The present study focuses on the machining performance of this newly developed alloy under high-speed turning conditions with advanced PCBN tools. Meanwhile, the machined surface integrity as influenced by cutting speed and feed rate was also investigated. The surface integrity was thoroughly characterized in terms of surface roughness and morphology, machining-induced plastic deformation, white layer formation, and residual stresses. It has been found that the cutting speed and feed rate had a strong effect on the cutting forces and resultant surface integrity. The cutting forces required when machining the alloy were gradually reduced with increasing cutting speed, while at 250 m/min and above, the flank tool wear became stronger which led to increased thrust force and feed force. A higher feed rate, on the other hand, always resulted in higher cutting forces. Increasing the cutting speed and feed rate in general deteriorated the surface integrity. High cutting speeds within the range of 200–250 m/min and a low feed rate of 0.1 mm/rev are preferable in order to implement more cost-effective machining without largely reducing the surface quality achieved. The formation of tensile residual stresses on the machined AD 730™, however, could be of a concern where good fatigue resistance is critical.

Place, publisher, year, edition, pages
Springer London, 2019
Keywords
Nickel-based superalloy, High-speed turning, Cutting forces, Surface integrity, AD730, Cubic boron nitride (CBN) tool
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-153292 (URN)10.1007/s00170-018-2792-1 (DOI)000458310400032 ()2-s2.0-85055531180 (Scopus ID)
Available from: 2018-12-10 Created: 2018-12-10 Last updated: 2019-03-05Bibliographically approved
Persson, H., Johansson, D., Chen, Z., Lenrich, F., M'Saoubi, R., Gustafsson, D., . . . Zhou, J. (2018). Modelling Tool Life in High Speed Machining of AD730™. In: Procedia Manufacturing 25 (2018) pp 316-321: . Paper presented at 8th Swedish Production Symposium, SPS 2018, 16-18 May 2018, Stockholm (pp. 316-321). , 25
Open this publication in new window or tab >>Modelling Tool Life in High Speed Machining of AD730™
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2018 (English)In: Procedia Manufacturing 25 (2018) pp 316-321, 2018, Vol. 25, p. 316-321Conference paper, Published paper (Refereed)
Keywords
Tool life, Superalloy, CBN, Colding, High speed machining
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-153291 (URN)10.1016/j.promfg.2018.06.089 (DOI)
Conference
8th Swedish Production Symposium, SPS 2018, 16-18 May 2018, Stockholm
Available from: 2018-12-10 Created: 2018-12-10 Last updated: 2018-12-10
Chen, Z., Zhou, J., Peng, R. L., M'Saoubi, R., Gustafsson, D., Palmert, F. & Moverare, J. (2018). Plastic Deformation and Residual Stress in High Speed Turning of AD730™ Nickel-based Superalloy with PCBN and WC Tools. In: Procedia CIRP 71 (2018) pp 440-445: . Paper presented at The 4th CIRP Conference on Surface Integrity, 11th-13th July, Tianjin, China (pp. 440-445). Elsevier, 71
Open this publication in new window or tab >>Plastic Deformation and Residual Stress in High Speed Turning of AD730™ Nickel-based Superalloy with PCBN and WC Tools
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2018 (English)In: Procedia CIRP 71 (2018) pp 440-445, Elsevier, 2018, Vol. 71, p. 440-445Conference paper, Published paper (Refereed)
Abstract [en]

A higher gas turbine efficiency can be achieved by increasing the operating temperature in hot sections. AD730™ is a recently-developed wrought/cast nickel-based superalloy which can maintain excellent mechanical properties above 700 ℃. However, machining of AD730™ could be a difficult task like other nickel-based superalloys. Therefore, studies are needed with respect to the machinability of this new alloy.

In this paper, high-speed turning was performed on AD730™ using polycrystalline cubic boron nitride (PCBN) tools and coated tungsten carbide (WC) tools at varied cutting speeds. The surface integrity was assessed in two important aspects, i.e., surface and sub-surface plastic deformation and residual stresses. The PCBN tools generally showed better performance compared with the WC tools since it led to reduced machining time without largely compromising the surface integrity achieved. The optimal cutting speed was identified in the range of 200-250 m/min when using the PCBN tools, which gives rise to a good combination of machining efficiency and surface integrity. The further increase of the cutting speed to 300 m/min resulted in severe and deep plastic deformation. Meanwhile, a continuous white layer was formed at the machined surface. When turning with the WC tools, the increased cutting speed from 80 m/min to 100 m/min showed very little effect with respect to the plastic deformation on the machined surface. It was found that tensile residual stresses were developed on all machined surfaces no matter when the PCBN or WC tools were used, and the surface tension was generally increased with increasing cutting speed. The tensile layer might need to be modified by e.g., post-machining surface treatments such as shot peening, if taking good fatigue performance into consideration.

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
plastic deformation, residual stress, nickel-based superalloy, AD730TM, high-speed turning
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-148484 (URN)10.1016/j.procir.2018.05.051 (DOI)
Conference
The 4th CIRP Conference on Surface Integrity, 11th-13th July, Tianjin, China
Available from: 2018-06-12 Created: 2018-06-12 Last updated: 2018-07-03
Zhou, J., Persson, H., Chen, Z., M'Saoubi, R., Gustafsson, D., Bushlya, V., . . . Peng, R. L. (2018). Surface Characterization of AD730™ Part Produced in High Speed Turning with CBN Tool. In: Elsevier (Ed.), Procedia CIRP 71 (2018): . Paper presented at 4th CIRP Conference on Surface Integrity (CSI 2018) (pp. 215-220). , 71
Open this publication in new window or tab >>Surface Characterization of AD730™ Part Produced in High Speed Turning with CBN Tool
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2018 (English)In: Procedia CIRP 71 (2018) / [ed] Elsevier, 2018, Vol. 71, p. 215-220Conference paper, Published paper (Refereed)
Keywords
AD730, Superalloy, Surface integrity, CBN, High Speed Machining
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-153290 (URN)10.1016/j.procir.2018.05.068 (DOI)
Conference
4th CIRP Conference on Surface Integrity (CSI 2018)
Available from: 2018-12-10 Created: 2018-12-10 Last updated: 2018-12-10
Chen, Z., Peng, R. L., Zhou, J., Bushlya, V., Saoubi, R. M., Johansson, S. & Moverare, J. (2017). Effect of Cutting Conditions on Machinability of AD 730 TM during High Speed Turning with PCBN Tools. In: : . Paper presented at EUROMAT17, Thessaloniki 17-21 September 2017,Greece (pp. 1-1).
Open this publication in new window or tab >>Effect of Cutting Conditions on Machinability of AD 730 TM during High Speed Turning with PCBN Tools
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2017 (English)Conference paper, Oral presentation with published abstract (Refereed)
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-143973 (URN)
Conference
EUROMAT17, Thessaloniki 17-21 September 2017,Greece
Available from: 2018-01-01 Created: 2018-01-01 Last updated: 2018-08-02Bibliographically approved
Chen, Z., Peng, R. L., Moverare, J., Avdovic, P., Zhou, J. & Johansson, S. (2016). Surface Integrity and Structural Stability of Broached Inconel 718 at High Temperatures. Metallurgical and Materials Transactions. A, 47A(7), 3664-3676
Open this publication in new window or tab >>Surface Integrity and Structural Stability of Broached Inconel 718 at High Temperatures
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2016 (English)In: Metallurgical and Materials Transactions. A, ISSN 1073-5623, E-ISSN 1543-1940, Vol. 47A, no 7, p. 3664-3676Article in journal (Refereed) Published
Abstract [en]

The current study focused on the surface integrity issues associated with broaching of Inconel 718 and the structural stability of the broached specimen at high temperatures, mainly involving the microstructural changes and residual stress relaxation. The broaching operation was performed using similar cutting conditions as that used in turbo machinery industries for machining fir-tree root fixings on turbine disks. Thermal exposure was conducted at 723 K, 823 K, and 923 K (450 A degrees C, 550 A degrees C, and 650 A degrees C) for 30, 300, and 3000 hours, respectively. Surface cavities and debris dragging, sub-surface cracks, high intensity of plastic deformation, as well as the generation of tensile residual stresses were identified to be the main issues in surface integrity for the broached Inconel 718. When a subsequent heating was applied, surface recrystallization and alpha-Cr precipitation occurred beneath the broached surface depending on the applied temperature and exposure time. The plastic deformation induced by the broaching is responsible for these microstructural changes. The surface tension was completely relaxed in a short time at the temperature where surface recrystallization occurred. The tensile layer on the sub-surface, however, exhibited a much higher resistance to the stress relief annealing. Oxidation is inevitable at high temperatures. The study found that the surface recrystallization could promote the local Cr diffusion on the broached surface.

Place, publisher, year, edition, pages
Springer, 2016
Keywords
Structural integrity, Broaching, Inconel 718, Plastic deformation, Residual stresses, Thermal exposure, Superalloy
National Category
Materials Engineering Other Materials Engineering
Identifiers
urn:nbn:se:liu:diva-111056 (URN)10.1007/s11661-016-3515-6 (DOI)000377434700041 ()
Funder
Linköpings universitet, 2009-00971
Note

The original title of this article when published in manuscript form was Structural integrity of broached Inconel 718 subjected to thermal exposure.

Available from: 2014-10-06 Created: 2014-10-06 Last updated: 2018-02-27Bibliographically approved
Zhou, J., Bushlya, V., Peng, R., Chen, Z., Johansson, S. & Stahl, J.-E. (2014). Analysis of Subsurface Microstructure and Residual Stresses in Machined Inconel 718 with PCBN and Al2O3-SiCw Tools. In: 2ND CIRP CONFERENCE ON SURFACE INTEGRITY (CSI): . Paper presented at 2nd CIRP Conference on Surface Integrity (CSI), Nottingham, UK, May 28-30, 2014 (pp. 150-155). Elsevier, 13
Open this publication in new window or tab >>Analysis of Subsurface Microstructure and Residual Stresses in Machined Inconel 718 with PCBN and Al2O3-SiCw Tools
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2014 (English)In: 2ND CIRP CONFERENCE ON SURFACE INTEGRITY (CSI), Elsevier, 2014, Vol. 13, p. 150-155Conference paper, Published paper (Refereed)
Abstract [en]

Subsurface microstructural alterations and residual stresses caused by machining significantly affect component lifetime and performance by influencing fatigue, creep, and stress corrosion cracking resistance. Assessing the surface quality of a machined part by characterizing subsurface microstructural alterations and residual stresses is essential for ensuring part performance and lifetime in aero-engines and power generators. This comparative study characterizes and analyzes subsurface microstructural alterations and residual stresses in Inconel 718 subjected to high-speed machining with PCBN and whisker-reinforced ceramic cutting tools. Effects of cutting tool materials and microgeometry on subsurface deformation, microstructural alterations, and residual stresses were investigated. Surface and subsurface regions of machined specimens were investigated using X-ray diffraction, electron channeling contrast imaging, and electron back-scatter diffraction to characterize microstructural alterations and measure deformation intensity and depth.

Place, publisher, year, edition, pages
Elsevier, 2014
Series
Procedia CIRP, ISSN 2212-8271 ; 13
Keywords
surface integrity, Inconel 718, residual stresses, microstructure, PCBN, ceramics
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-106779 (URN)10.1016/j.procir.2014.04.026 (DOI)000360720300026 ()
Conference
2nd CIRP Conference on Surface Integrity (CSI), Nottingham, UK, May 28-30, 2014
Available from: 2014-05-22 Created: 2014-05-22 Last updated: 2016-05-26Bibliographically approved
Chen, Z., Peng, R., Avdovic, P., Moverare, J., Karlsson, F., Zhou, J. & Johansson, S. (2014). Analysis of Thermal Effect on Residual Stresses of Broached Inconel 718. In: : . Paper presented at ECRS9 6-10 July, Troyes, Frankrike (pp. 574-579). Trans Tech Publications Inc., 996
Open this publication in new window or tab >>Analysis of Thermal Effect on Residual Stresses of Broached Inconel 718
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2014 (English)Conference paper, Published paper (Refereed)
Abstract [en]

Inconel 718 is a nickel based superalloy that is widely used as a turbine disc material in gas turbine industries. This study details the effect of thermal exposure on the residual stresses produced when broaching Inconel 718. The chosen parameters for broaching in this study are similar to those used when manufacturing turbine discs. The broaching operation produced a high level of tensile residual stresses at the broached surface. A layer with tensile residual stresses was formed in the sub-surface region, followed by a layer several times thicker with compressive residual stresses. Thermal exposure was conducted at 550 °C. The depth distributions of residual stresses after thermal exposure are presented and discussed in this paper. Complete relaxation of the surface tensile residual stresses was observed after 30 h thermal exposure, whereas the 3000 h thermal exposure influenced both the surface and sub-surface residual stress states.

Place, publisher, year, edition, pages
Trans Tech Publications Inc., 2014
Series
Advanced Materials Research, ISSN 1022-6680 ; 996
Keywords
Broaching, Incone 718, Residual Stresses, Thermal Exposure, Recrystallization
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-111057 (URN)10.4028/www.scientific.net/AMR.996.574 (DOI)000348282100093 ()
Conference
ECRS9 6-10 July, Troyes, Frankrike
Available from: 2014-10-06 Created: 2014-10-06 Last updated: 2015-02-20Bibliographically approved
Chen, Z., Moverare, J., Peng, R. L. & Johansson, S. (2014). Damage analysis of a retired gas turbine disc. In: Proceedings of the 2014 Energy Materials Conference: . Paper presented at Energy Materials 2014 TMS, November 4-6, 2014, Xi’an, China (pp. 405-410). John Wiley & Sons
Open this publication in new window or tab >>Damage analysis of a retired gas turbine disc
2014 (English)In: Proceedings of the 2014 Energy Materials Conference, John Wiley & Sons, 2014, p. 405-410Conference paper, Published paper (Refereed)
Abstract [en]

Gas turbine discs operate mostly at high temperature gradients and are subjected to mechanical loads simultaneously. The high thermal and mechanical loads eventually could result in degradation and damages in disc material, thereby increasing the risk of disc failure. In this study, a damage analysis was performed in a retired gas turbine disc made of Inconel 718. Oxidation attack and microstructural degradation as the consequence of the high service temperature have been found to be the main damages that take place in the non-contact area of the retired disc. In the blade/disc contact area, fretting fatigue occurs, with a result that cracks initiate from the oxide/metal interface and propagate in the disc alloy parallel to the sliding direction of fretting, consequently reducing the stability and safety of the disc. Meantime, oxygen diffuses into the fretting fatigue cracks, thereby exacerbating the oxidation attack. A multi-layered scale with periodic formation of the Fe-oxide/spinel layer and the metallic layer is formed on the contact surface. In both contact and non-contact area, recrystallization and α-Cr precipitation take place in the surface layer of the disc alloy. The locations where α-Cr precipitates are commonly considered to be the natural sites for mechanical weakness.

Place, publisher, year, edition, pages
John Wiley & Sons, 2014
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-111060 (URN)000364592900047 ()978-1-119-02794-2 (ISBN)
Conference
Energy Materials 2014 TMS, November 4-6, 2014, Xi’an, China
Available from: 2014-10-06 Created: 2014-10-06 Last updated: 2015-12-07Bibliographically approved
Chen, Z., Peng, R., Avdovic, P., Zhou, J., Moverare, J., Karlsson, F. & Johansson, S. (2014). Effect of thermal exposure on microstructure and nano-hardness of broached Inconel 718. In: J.Y. Guédou and J. Choné (Ed.), MATEC Web of Conferences Vol. 14 (2014) EUROSUPERALLOYS 2014 – 2nd European Symposium on Superalloys and their Applications: Session 8: Recrystallization and Grain Growth. Paper presented at 2nd European Symposium on Superalloys and Their Applications, May 12-16, 2014, French Riviera, Giens, France (pp. 08002-p.1-08002-p.6). Les Ulis, France: E D P Sciences
Open this publication in new window or tab >>Effect of thermal exposure on microstructure and nano-hardness of broached Inconel 718
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2014 (English)In: MATEC Web of Conferences Vol. 14 (2014) EUROSUPERALLOYS 2014 – 2nd European Symposium on Superalloys and their Applications: Session 8: Recrystallization and Grain Growth / [ed] J.Y. Guédou and J. Choné, Les Ulis, France: E D P Sciences , 2014, p. 08002-p.1-08002-p.6Conference paper, Published paper (Refereed)
Abstract [en]

Inconel 718 is a high strength, heat resistant superalloy that is used extensively for components in hot sections of gas turbine engines. This paper presents an experimental study on the thermal stability of broached Inconel 718 in terms of microstructure and nano-hardness. The broaching process used in this study is similar to that used in gas turbine industries for machining fir-tree root fixings on turbine discs. Severe plastic deformation was found under the broached surface. The plastic deformation induces a work-hardened layer in the subsurface region with a thickness of ∼50 μm. Thermal exposure was conducted at two temperatures, 550 C and 650 C respectively, for 300 h. Recrystallization occurs in the surface layer during thermal exposure at 550 C and α-Cr precipitates as a consequence of the growth of recrystallized δ phases. More recrystallized grains with a larger size form in the surface layer and the α-Cr not only precipitates in the surface layer, but also in the sub-surface region when the thermal exposure temperature goes up to 650 C. The thermal exposure leads to an increase in nano-hardness both in the work-hardened layer and in the bulk material due to the coarsening of the main strengthening phase γ′′.

Place, publisher, year, edition, pages
Les Ulis, France: E D P Sciences, 2014
Series
MATEC Web of Conferences, ISSN 2261-236X ; Volume 14
Keywords
Structural integrity, Broaching, Inconel 718, Plastic deformation, Residual stresses, Thermal exposure, Superalloy
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-111058 (URN)10.1051/matecconf/20141408002 (DOI)000351930400024 ()2-s2.0-84906910411 (Scopus ID)
Conference
2nd European Symposium on Superalloys and Their Applications, May 12-16, 2014, French Riviera, Giens, France
Available from: 2014-10-06 Created: 2014-10-06 Last updated: 2016-09-07Bibliographically approved
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