A method of making a powder metallurgy superalloy component having an inclusion

Abstract

The application relates to a preparation method of a powder high-temperature alloy component containing inclusions, and relates to the technical field of powder metallurgy and the technical field of air engine airworthiness certification evaluation. The preparation method comprises the following steps: based on the size of a required powder high-temperature alloy component, a sleeve for powder metallurgical forming is prepared, the sleeve is cut into multiple parts to obtain multiple sleeve units; the inclusion implantation position is located at the cutting position of the sleeve; high-temperature alloy powder is loaded into each sleeve unit, and then vacuum sintering treatment is carried out, so that the high-temperature alloy powder in each sleeve unit is solidified into a high-temperature alloy part; multiple high-temperature alloy parts are combined to obtain a powder high-temperature alloy assembly; during the combining process, inclusions need to be implanted at the inclusion implantation position; and the powder high-temperature alloy assembly is subjected to hot isostatic pressing treatment to obtain a powder high-temperature alloy component containing inclusions. The application is used for improving the accuracy of simulation of real components to meet the urgent needs of airworthiness certification.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of powder metallurgy and the field of air engine airworthiness certification evaluation, in particular to a preparation method of a powder high-temperature alloy component containing inclusions. BACKGROUND

[0002] With the development of air engines, the performance requirements of the engine are continuously improved, making the service environment of the air engine more severe. The performance requirements of the core component materials such as turbine disc, blade and combustion chamber are also continuously improved. High-temperature alloys with high strength, good oxidation resistance and heat corrosion resistance are widely used in the field of aerospace and have gradually become the preferred material for key heat-resistant components such as engine turbine discs.

[0003] The casting / forging process of high-temperature alloys often adds a large amount of strengthening elements such as Nb, Ti, Co, Cr and Mo in order to improve the strength of the alloy, but at the same time, it also brings disadvantages such as composition segregation and processing difficulty. The nickel-based powder high-temperature alloy manufactured by powder metallurgy process has the advantages of fine grain, uniform structure, high alloying degree, excellent mechanical properties and thermal process performance. Powder high-temperature alloy is the best material for high thrust-to-weight ratio air engine turbine discs.

[0004] The emergence of powder high-temperature alloy production process solves the problems of element segregation, non-uniform structure and poor thermal processing performance of traditional nickel-based alloys. However, due to factors such as alloy composition design defects and unstable process heat treatment technology, some defects often exist in powder high-temperature alloys. Among them, the original particle boundary (PPB), thermal induced pore (TIP) and non-metallic inclusions are the three major defect problems in powder high-temperature alloys. These defects will seriously affect the mechanical properties and service life of powder high-temperature alloy turbine discs, and are an important factor affecting the safety of the engine.

[0005] At present, the original particle boundary defect (PPB) and the thermal induced pore defect (TIP) can be basically controlled through alloy composition optimization and preparation process control. Inclusion has become a problem that restricts the development and application of powder high-temperature alloy and needs to be solved urgently. Therefore, it is urgent to carry out probability risk assessment on powder high-temperature alloy components, and the prerequisite for carrying out related evaluation research is to prepare powder high-temperature alloy components containing inclusions.

[0006] Currently, the preparation method of the prior art powder high-temperature alloy component containing inclusions mainly comprises the following steps: firstly, mixing the inclusion particles with the alloy powder, and then preparing the powder high-temperature alloy component according to the preparation method of the high-temperature alloy component. However, the number, position and distribution state of the inclusions in the powder high-temperature alloy component containing inclusions prepared by the method are uncontrollable, the internal inclusions of the real component cannot be simulated, and the error of the overall component life is extremely large. Therefore, the preparation method of the powder high-temperature alloy component containing inclusions cannot meet the demand of airworthiness certification of the powder high-temperature alloy component.

[0007] In summary, there is an urgent need for a preparation method of a powder high-temperature alloy component containing inclusions, which can control the type, size, position and the like of defects, improve the accuracy of simulating the real component, reduce the error, meet the urgent demand of airworthiness certification, and make the airworthiness certification related research proceed smoothly. SUMMARY

[0008] Therefore, the present application provides a preparation method of a powder high-temperature alloy component containing inclusions, which aims to improve the accuracy of simulating the real component, reduce the error, meet the urgent demand of airworthiness certification, and make the airworthiness certification related research proceed smoothly.

[0009] To achieve the above-mentioned purpose, the present application mainly provides the following technical solutions:

[0010] In one aspect, the embodiment of the present application provides a preparation method of a powder high-temperature alloy component containing inclusions, which comprises the following steps:

[0011] The preparation of the sleeve unit step: based on the size of the required powder high-temperature alloy component, a sleeve for powder metallurgy forming is prepared, and the sleeve is cut into multiple parts to obtain multiple sleeve units; wherein the inclusion implantation position is located at the cutting position of the sleeve;

[0012] The preparation of the powder high-temperature alloy part step: high-temperature alloy powder is loaded into each sleeve unit, and then vacuum sintering treatment is performed to solidify the high-temperature alloy powder in each sleeve unit into a high-temperature alloy part;

[0013] The combination step: multiple high-temperature alloy parts are combined to obtain a powder high-temperature alloy assembly; wherein in the combination process, inclusions need to be implanted at the inclusion implantation position;

[0014] The hot isostatic pressing treatment step: the powder high-temperature alloy assembly is subjected to hot isostatic pressing treatment to obtain a powder high-temperature alloy component containing inclusions.

[0015] Preferably, the inclusions are one or more of Al2O3, SiO2, rubber, fiber and heterogeneous metal particles.

[0016] Preferably, before the step of preparing the can unit, further comprising:

[0017] The simulation step: using simulation software to simulate the preparation process of the powder superalloy component to determine the implantation position of the inclusions; preferably, the simulation step can also determine the size of the inclusions; preferably, the simulation software is selected from any one of MSC simulation software, ANSYS simulation software and ABAQUS simulation software.

[0018] Preferably, in the simulation step: based on the physical properties of the formed superalloy material, the internal stress concentration area, the shrinkage change of the powder in the can during the forming process and the final implantation position of the inclusions, the preparation process of the powder superalloy component is simulated by simulation software to determine the implantation position of the inclusions by reverse calculation. Preferably, the simulation software is used to simulate the failure process of inclusions of different sizes to determine the effective size of the implanted inclusions.

[0019] Preferably, before the step of preparing the can unit, further comprising:

[0020] The grading treatment step: grading treatment of inclusions to obtain inclusions of different size ranges; preferably, the size of the inclusions is one or more of 50 μm-100 μm, 100 μm-300 μm and 300 μm-500 μm.

[0021] Preferably, the powder superalloy component containing inclusions is a powder superalloy turbine disc component containing inclusions.

[0022] Preferably, in the step of preparing the can unit: the material of the can is low carbon steel or stainless steel.

[0023] Preferably, in the step of preparing the powder superalloy component: loading superalloy powder into each can unit and performing vibration treatment; performing vacuum sintering treatment on the vibration treated can unit; and / or the temperature of the vacuum sintering treatment is 900°C-1050°C; the vacuum degree of the vacuum sintering treatment is 10 -2 Pa-10 -3 Pa; the time of the vacuum sintering treatment is 0.5h-1.5h.

[0024] Preferably, in the combining step: after combining a plurality of superalloy components, the outer periphery of the combined interface is sealed to obtain a powder superalloy combined component.

[0025] Preferably, in the hot isostatic pressing treatment step: the temperature of the hot isostatic pressing treatment is 1150°C-1280°C; the pressure of the hot isostatic pressing treatment is 120MPa-160MPa; the time of the hot isostatic pressing treatment is 2h-4h.

[0026] Compared with the prior art, the method for preparing the powder superalloy component containing inclusions has at least the following beneficial effects:

[0027] The embodiment of the present application provides a method for preparing a powder superalloy component containing inclusions, which comprises the following steps: based on the size of a required powder superalloy component, a sleeve for powder metallurgical forming is prepared, and the sleeve is cut into multiple parts to obtain multiple sleeve units; wherein, the implantation position of the inclusions is located at the cutting position of the sleeve; high-temperature alloy powder is loaded into each sleeve unit, and then vacuum sintering treatment is performed, so that the high-temperature alloy powder in each sleeve unit is solidified into a high-temperature alloy part; multiple high-temperature alloy parts are combined to obtain a powder superalloy assembly; wherein, during the combining process, inclusions are implanted at the implantation position of the inclusions; the powder superalloy assembly is subjected to hot isostatic pressing treatment to obtain a powder superalloy component containing inclusions. It can be known from the above steps that the scheme of the present application can realize artificial control of defect types, sizes, positions and the like, can simulate the internal defect conditions of various components according to the needs of different types of component airworthiness certification, and only one hot isostatic pressing treatment is required in the whole process, which improves the simulation accuracy, reduces errors (two hot isostatic pressing treatments will reduce defects, and are not consistent with the preparation process of the real component, and the error is large), lays a material foundation for the prediction of the life of the powder superalloy integral disc containing internal defects and the failure probability analysis research, and provides technical support for the airworthiness certification of domestic aero-engines.

[0028] The above description is only a summary of the technical scheme of the present application. In order to more clearly understand the technical means of the present application and can be implemented according to the content of the specification, the following will be described in detail with the preferred embodiment of the present application and with the help of the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 is a preparation flowchart of a method for preparing a powder superalloy component containing inclusions provided by the embodiment of the present application;

[0030] Figure 2 is a simulation diagram of a stress concentration area of the component in example 1 and an implantation position diagram of 100 mu m Al2O3 inclusions; wherein, (a) is a simulation diagram of a stress concentration area of the component, and the red area is a stress concentration area, which is a defect implantation position, (b) is a defect (100 mu m Al2O3 inclusions) implantation position diagram;

[0031] Figure 3 is a GH4169 powder superalloy component containing Al2O3 inclusions prepared in example 1 and detection results; wherein, Figure 3Figure (a) in the drawing is a GH4169 powder superalloy component containing Al2O3 inclusions; Figure 3 Figure (b) in the drawing is a water immersion ultrasonic testing result diagram of the GH4169 powder superalloy component containing Al2O3 inclusions in the drawing;

[0032] Figure 4 Figure (a) in the drawing is a component stress concentration area simulation diagram and a schematic diagram of the implantation position of SiO2 inclusions of 100 μm, 300 μm and 500 μm in Example 2; wherein, (a) is a component stress concentration area simulation diagram, the red area is a stress concentration area, which is a defect implantation position, (b) is a defect (SiO2 inclusions of 100 μm, 300 μm and 500 μm) implantation position diagram;

[0033] Figure 5 Figure (b) in the drawing is a water immersion ultrasonic testing result diagram of the GH4099 powder superalloy component containing SiO2 inclusions prepared in Example 2.

[0034] Figure 6 Figure (a) in the drawing is a component stress concentration area simulation diagram and a schematic diagram of the implantation position of Al2O3 inclusions of 400 μm and SiO2 inclusions in Example 3; wherein, (a) is a component stress concentration area simulation diagram, the red area is a stress concentration area, which is a defect implantation position, (b) is a defect (Al2O3 inclusions of 400 μm and SiO2 inclusions) implantation position diagram;

[0035] Figure 7 Figure (b) in the drawing is a water immersion ultrasonic testing result diagram of the GH4099 powder superalloy component containing SiO2 inclusions prepared in Example 3. DETAILED DESCRIPTION

[0036] In order to further clarify the technical means and effects taken by the present application to achieve the predetermined purposes, the specific embodiments, structures, features and effects according to the present application are described in detail below in combination with the drawings and preferred embodiments. In the following description, different "an embodiment" or "embodiments" do not necessarily refer to the same embodiment. In addition, the specific features, structures or characteristics in one or more embodiments can be combined in any suitable form.

[0037] The present application provides a preparation method of a powder superalloy component containing inclusions, as shown in the drawing, which comprises the following steps: Figure 1

[0038] The step of grading treatment: the inclusions are subjected to grading treatment to obtain inclusions of different size ranges; preferably, the size of the inclusions is one or several of 50 μm-100 μm, 100 μm-300 μm and 300 μm-500 μm.

[0039] ​Preferably, the inclusions are one or more of Al2O3, SiO2, rubber, fiber, and heterogeneous metal particles. The heterogeneous metal particles herein refer to particles that are different from the composition of the base material.

[0040] It is noted herein that the size of the inclusions can be determined based on practice and experience, or based on simulation.

[0041] Simulation step: the simulation software is used to simulate the preparation process of the powder superalloy component to determine the implantation position of the inclusions and the size of the inclusions.

[0042] Preferably, the simulation software is selected from any one of MSC simulation software, ANSYS simulation software, and ABAQUS simulation software.

[0043] Specifically, based on the physical properties of the formed superalloy material (the physical properties herein refer to loose bulk density, tap density, particle size distribution, sphericity, etc.), internal stress concentration area, shrinkage change of the powder in the can during the forming process, and the final implantation position of the inclusions, the simulation software is used to simulate the preparation process of the powder superalloy component to determine the implantation position of the inclusions by reverse calculation. Preferably, at the same time, the simulation software is used to simulate the failure process of inclusions of different sizes to determine the effective size of the implanted inclusions.

[0044] The internal stress concentration area is determined by relevant simulation software (such as any one of MSC simulation software, ANSYS simulation software, and ABAQUS simulation software), and the simulation results are provided according to the geometry of the component and the service conditions.

[0045] The shrinkage process of the can during the forming process can be simulated by relevant simulation software (any one of MSC simulation software, ANSYS simulation software, and ABAQUS simulation software).

[0046] The final implantation position of the inclusions is the position given by the simulation results, which is the result of comprehensive simulation based on the geometry of the component and the service conditions, mainly simulating the most dangerous service condition of the component.

[0047] This step is specifically as follows:

[0048] 1) First, the inclusion is regarded as a particle, and based on the physical properties of the material, the parameters of hot isostatic pressing, and the structure of the can, the motion trajectory of the particle during hot isostatic pressing is simulated; then, taking the final implantation position as the target position, the initial position of the particle is solved reversely based on the simulated motion trajectory of the particle, and multiple initial positions of defects are obtained during the simulation process, from which the position of the defect that is easy to implant is selected as the final implantation position of the defect.

[0049] 2) The different size inclusions can be determined by simulation to correspond to the component life in theory, when the component life is lower than a certain value, the result is not of engineering significance, so the size of the inclusion is invalid, and the effective size of the inclusion is the size of the defect under the premise of engineering, which is given according to the combination configuration of the component, material performance and service conditions and other factors.

[0050] Preferably, the inclusion-containing powder superalloy component is an inclusion-containing powder superalloy turbine disk.

[0051] The preparation of the sleeve unit step: based on the size of the required powder superalloy component, a sleeve for powder metallurgical forming is prepared, and the sleeve is cut into multiple parts to obtain multiple sleeve units; wherein the inclusion implantation position is located at the cutting position of the sleeve.

[0052] Preferably, the material of the sleeve is low-carbon steel or stainless steel.

[0053] The preparation of the powder superalloy component step: high-temperature alloy powder is loaded into each sleeve unit, and then vacuum sintering treatment is performed to solidify the high-temperature alloy powder in each sleeve unit into a high-temperature alloy component.

[0054] Preferably, high-temperature alloy powder is loaded into each sleeve unit, and vibration compaction treatment is performed; the sleeve unit after vibration compaction treatment is subjected to vacuum sintering treatment.

[0055] The temperature of the vacuum sintering treatment is 900-1050℃; the vacuum degree of the vacuum sintering treatment is 10 -2 Pa-10 -3 Pa; the time of the vacuum sintering treatment is 0.5-1h.

[0056] The combination step: multiple high-temperature alloy components are combined to obtain a powder superalloy assembly; wherein, during the combination process, inclusions are implanted at the inclusion implantation position.

[0057] Preferably, after the combination of multiple high-temperature alloy components, sealing welding is performed on the outer periphery of the combination interface to obtain a powder superalloy assembly. It should be noted that if sealing welding is not performed, the requirement of hot isostatic pressing process cannot be met, which requires that a pressure difference be formed between the inside and outside of the component. If sealing welding is not performed, the internal and external pressure difference is 0.

[0058] The hot isostatic pressing treatment step: the powder superalloy assembly is subjected to hot isostatic pressing treatment to obtain an inclusion-containing powder superalloy component.

[0059] Preferably, the temperature of the hot isostatic pressing treatment is 1150-1280℃; the pressure of the hot isostatic pressing treatment is 120-160MPa; and the time of the hot isostatic pressing treatment is 2-4h.

[0060] Here, the above-mentioned scheme of the embodiment of the present application needs to be described as follows:

[0061] 1) The scheme of the embodiment of the present application is not limited to high-temperature alloy materials and inclusion types, and can be applied to the preparation of various types of high-temperature alloy inclusion-containing integral components (such as disc components) involved in aero-engine according to the requirements of airworthiness certification.

[0062] (2) The method provided by the present application can realize artificial control of defect types, sizes, positions, etc., and can simulate the internal defect conditions of various components (such as disc components) according to the requirements of airworthiness certification of different types of disc components, thereby laying a material foundation for the prediction of the life of internal defect-containing powder high-temperature alloy integral components and the failure probability analysis research, and providing technical support for the airworthiness certification of domestic aero-engines.

[0063] (3) The present application overcomes the shortcomings of the prior art, and can ensure the accuracy of subsequent experimental results and the smooth progress of airworthiness certification related research.

[0064] The following will be further described through specific experimental embodiments as follows:

[0065] Embodiment 1

[0066] This embodiment prepares a GH4169 powder high-temperature alloy component containing Al2O3 inclusions, which comprises the following steps:

[0067] The grading treatment step: the Al2O3 inclusions are graded and treated to obtain Al2O3 inclusions with a size of 100μm.

[0068] The simulation step: ABAQUS simulation software is used to simulate the preparation process of the GH4169 powder high-temperature alloy component, and the implantation position of the inclusions is determined, wherein the implantation position of the inclusions is the stress concentration area on one side of the component, as shown in Figure 2 .

[0069] The preparation of the sleeve unit step: based on the three-dimensional size of the GH4169 powder high-temperature alloy component, a sleeve for powder metallurgy forming is prepared, and the sleeve is cut into two parts to obtain two sleeve units, and the implantation position of the inclusions is located at the cutting position;

[0070] The steps for preparing powder metallurgy high-temperature alloy components are as follows: High-temperature alloy powder for powder metallurgy forming is loaded into the prepared cladding unit and compacted using a vibration treatment with an amplitude of 4 mm, a vibration frequency of 250 times / min, and a vibration time of 30 min. The compacted cladding unit is then placed in a vacuum sintering furnace for sintering at 1000℃ under a vacuum degree of 2×10⁻⁶. -2 Pa, vacuum sintering time of 0.5h, preliminary preparation of GH4169 high-temperature powder high-temperature alloy parts.

[0071] Assembly steps: The two high-temperature alloy components are assembled, and Al2O3 inclusions are implanted at predetermined positions. The outer periphery of the assembly interface is sealed by welding to obtain the powder high-temperature alloy assembly.

[0072] Hot isostatic pressing (HIP) process: Based on the principle of high-temperature diffusion of elements, the powder high-temperature alloy assembly is subjected to HIP. The HIP temperature is 1180℃, the HIP pressure is 150MPa, and the HIP time is 4h, thereby preparing a powder high-temperature alloy component containing inclusions for airworthiness certification research.

[0073] See Figure 3 As shown, this embodiment successfully implanted Al2O3 inclusions at predetermined locations in a GH4169 powder superalloy component.

[0074] Example 2

[0075] This embodiment prepares a GH4099 powder high-temperature alloy component containing SiO2 inclusions, including the following steps:

[0076] Grading process: The SiO2 inclusions are graded to obtain SiO2 inclusions with sizes of 100μm, 300μm and 500μm.

[0077] Simulation steps: The fabrication process of GH4099 powder superalloy components was simulated using ANSYS software to determine the insertion locations of inclusions. The insertion locations of inclusions were identified as different stress concentration areas within the component. (See [link to simulation steps]). Figure 4 As shown.

[0078] Preparation steps of the cladding unit: Based on the three-dimensional dimensions of the GH4099 powder high-temperature alloy component, a cladding for powder metallurgy forming is prepared, and the cladding is divided into two parts to obtain two cladding units. The division position is the insertion position of the inclusion.

[0079] The step of preparing the powder superalloy component comprises the following steps: loading the powder metallurgical forming superalloy powder into the prepared canning unit and performing a vibration treatment with an amplitude of 5 mm, a vibration frequency of 350 times / min and a vibration time of 20 min; placing the vibration-treated canning unit in a vacuum sintering furnace to perform a sintering treatment at 1050°C, a vacuum degree of 8x10 -3 Pa, and a vacuum sintering treatment time of 0.5 h, to preliminarily prepare a GH4099 powder superalloy component.

[0080] The step of combining comprises the following steps: combining the two parts of the superalloy component, and implanting SiO2 inclusions of different sizes at predetermined positions, and sealing the outer periphery of the combined interface.

[0081] The step of hot isostatic pressing treatment comprises the following steps: based on the principle of element high-temperature diffusion, performing a hot isostatic pressing treatment on the combined powder superalloy component as a whole, a hot isostatic pressing treatment temperature of 1210°C, a hot isostatic pressing treatment pressure of 160 MPa, and a hot isostatic pressing treatment time of 3 h, to prepare an in-flight certification research powder superalloy component containing inclusions.

[0082] As shown in Figure 5 , the embodiment successfully implants SiO2 inclusions of 100 μm, 300 μm and 500 μm at predetermined positions in the GH4099 powder superalloy component.

[0083] Example 3

[0084] The embodiment prepares a GH4096M powder superalloy component containing Al2O3 inclusions and SiO2 inclusions, comprising the following steps:

[0085] The step of grading treatment comprises the following steps: grading treatment of the Al2O3 inclusions and the SiO2 inclusions to obtain Al2O3 inclusions and SiO2 inclusions with a size of 400 μm.

[0086] The step of simulation comprises the following steps: using ABAQUS simulation software to simulate the preparation process of the GH4096M powder superalloy component, to determine the implantation positions of the two kinds of inclusions, as shown in Figure 6 , the implantation positions of the inclusions are the stress concentration areas on the symmetric sides of the component.

[0087] The step of preparing the canning unit comprises the following steps: based on the three-dimensional size of the GH4096M powder superalloy component, preparing a powder metallurgical forming canning, and cutting the canning into two parts to obtain two canning units, and the cutting position is the implantation position of the inclusions.

[0088] The step of preparing the powder high-temperature alloy component includes the following steps: a powder high-temperature alloy powder for powder metallurgy forming is loaded into the prepared can and is subjected to a vibration compaction treatment, the vibration amplitude is 7 mm, the vibration frequency is 300 times / min, and the vibration time is 35 min; the can after the vibration compaction treatment is placed in a vacuum sintering furnace for sintering treatment at 1030°C, the vacuum degree is 1x10 -2 Pa, the vacuum sintering treatment time is 1 h, and a GH4096M high-temperature powder high-temperature alloy component is preliminarily prepared.

[0089] The step of combining includes the following steps: the two parts of the high-temperature alloy component are combined, and the Al2O3 inclusions and the SiO2 inclusions are implanted at the predetermined positions.

[0090] The step of hot isostatic pressing treatment includes the following steps: based on the principle of element high-temperature diffusion, the whole powder high-temperature alloy component after the combination is subjected to hot isostatic pressing treatment, the hot isostatic pressing treatment temperature is 1180°C, the hot isostatic pressing treatment pressure is 145 MPa, and the hot isostatic pressing treatment time is 3.5 h, so that the powder high-temperature alloy component containing inclusions for airworthiness certification research is prepared.

[0091] As shown in Figure 7 , the embodiment successfully implants the Al2O3 inclusions and the SiO2 inclusions with a size of 400 μm at the predetermined positions in the GH4096M powder high-temperature alloy component.

[0092] Comparative Example 1

[0093] The step of preparing a GH4169 powder high-temperature alloy component containing Al2O3 inclusions includes the following steps:

[0094] (1) The Al2O3 inclusions are subjected to a grading treatment to obtain Al2O3 inclusions with a size of 100 μm;

[0095] (2) The Al2O3 inclusion powder with a size of 100 μm is mixed with a GH4169 powder;

[0096] (3) The mixed powder is loaded into a can, and is subjected to hot isostatic pressing treatment, the hot isostatic pressing treatment temperature is 1180°C, the hot isostatic pressing treatment pressure is 150 MPa, and the hot isostatic pressing treatment time is 4 h, so that the powder high-temperature alloy component containing inclusions is prepared.

[0097] The problem of the component prepared by the method is that the defect position is uncontrollable, and the research requirement of airworthiness certification cannot be met. On the one hand, the powder for hot isostatic pressing is prepared by mixing two kinds of powders, so that the inclusion powder position is randomly generated after mixing and is uncontrollable. On the other hand, after the mixed powder is loaded into the package, the inclusion powder position after loading into the package is also uncontrollable due to the flow of the powder itself. Based on the above two factors, the internal defect position of the formed component is random, which cannot meet the research and evaluation requirements of airworthiness certification.

[0098] Comparative Example 2

[0099] Comparative Example 2 prepares a GH4169 powder superalloy component containing Al2O3 inclusions, including the following steps:

[0100] (1) The Al2O3 inclusions are classified and treated to obtain Al2O3 inclusions with a size of 100 μm;

[0101] (2) The superalloy component is prepared according to the normal hot isostatic pressing component preparation process, the hot isostatic pressing temperature is 1180℃, the hot isostatic pressing pressure is 150MPa, and the hot isostatic pressing time is 4h;

[0102] (3) The prepared component is cut according to the defect implantation position, and Al2O3 inclusions are implanted at the predetermined position;

[0103] (4) The component after implanting the defect is sealed and welded, and is subjected to hot isostatic pressing treatment, the hot isostatic pressing temperature is 1180℃, the hot isostatic pressing pressure is 150MPa, and the hot isostatic pressing time is 4h, so as to prepare a powder superalloy component containing inclusions.

[0104] The problem of the component prepared by the method is that: the internal organization and performance of the component change due to the preparation process, which is inconsistent with the actual component state, and cannot meet the research requirements of airworthiness certification. Since the method is subjected to two times of hot isostatic pressing treatment, the organization of the formed component is coarsened compared with the actual component, the strength of the component is reduced, the plasticity is increased, the service state of the actual component containing Al2O3 inclusions cannot be simulated, and the research and evaluation requirements of airworthiness certification cannot be met.

[0105] The above is only a preferred embodiment of the present application, and does not limit the present application in any form. Any simple modification, equivalent change and modification of the above embodiment based on the technical essence of the present application still belongs to the scope of the technical solution of the present application.​​​​​​​​

Claims

1. A method of producing a powder superalloy component containing inclusions, characterized in that, It comprises the following steps: The simulation step: the preparation process of the powder superalloy component is simulated by using simulation software to determine the implantation position of the inclusions; wherein, based on the physical properties of the formed superalloy material, the internal stress concentration area, the shrinkage change of the powder in the can during the forming process and the final implantation position of the inclusions, the preparation process of the powder superalloy component is simulated by using simulation software, and the implantation position of the inclusions is determined by backstepping; The preparation of the can unit step: based on the size of the required powder superalloy component, the powder metallurgy forming can is prepared, and the can is cut into multiple parts to obtain multiple can units; wherein, the implantation position of the inclusions is located at the cutting position of the can; The preparation of the powder superalloy component step: the high-temperature alloy powder is loaded into each can unit, and then vacuum sintering treatment is carried out, so that the high-temperature alloy powder in each can unit is solidified into a high-temperature alloy component; The combination step: multiple high-temperature alloy components are combined to obtain a powder superalloy assembly; wherein, during the combination process, the inclusions need to be implanted at the implantation position of the inclusions; The hot isostatic pressing treatment step: the powder superalloy assembly is subjected to hot isostatic pressing treatment to obtain a powder superalloy component containing inclusions.

2. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, The inclusions are one or more of Al2O3, SiO2, rubber, fiber and heterogeneous metal particles.

3. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, The simulation step can also determine the size of the inclusions.

4. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, The simulation software is selected from any one of MSC simulation software, ANSYS simulation software and ABAQUS simulation software.

5. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, In the simulation step: the failure process of inclusions of different sizes is simulated by using simulation software to determine the effective size of the implanted inclusions.

6. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, Before the preparation of the can unit step, it further comprises: The grading treatment step: the inclusions are subjected to grading treatment to obtain inclusions of different size ranges.

7. The preparation method of the powder superalloy component containing inclusions according to claim 6, wherein The size of the inclusions is one or more of 50-100 μm, 100-300 μm and 300-500 μm.

8. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, The powder superalloy component containing inclusions is a powder superalloy turbine disk containing inclusions.

9. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, In the preparation of the can unit step: the material of the can is low-carbon steel or stainless steel.

10. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, In the preparation of the powder superalloy component step: The high-temperature alloy powder is loaded into each can unit, and vibration treatment is carried out; the can unit after vibration treatment is subjected to vacuum sintering treatment.

11. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, In the preparation of the powder superalloy component step: The temperature of the vacuum sintering treatment is 900-1050℃; the vacuum degree of the vacuum sintering treatment is 10 -2 -10 -3 Pa; the time of the vacuum sintering treatment is 0.5-1.5h.

12. The method of producing an inclusion-containing powder superalloy component according to claim 1, characterized by, In the combination step: After the combination of multiple high-temperature alloy components, the outer periphery of the combination interface is sealed and welded to obtain a powder superalloy assembly.

13. The method of claim 1, wherein the method further comprises: In the hot isostatic pressing treatment step: The temperature of the hot isostatic pressing treatment is 1150-1280℃; the pressure of the hot isostatic pressing treatment is 120-160 MPa; the time of the hot isostatic pressing treatment is 2-4 h.

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