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<p>Nickel-based superalloys are widely used in aerospace, automotive, and precision machinery due to their excellent properties. The microstructure and mechanical properties of machined surfaces critically affect component performance and lifespan. However, the mechanisms of microstructural changes (e.g., phase transformation and grain refinement) caused by mechanical-thermal coupling during grinding and their impact on material properties are not fully understood. This study investigates the effects of grinding on the microstructure and mechanical properties of machined surfaces, providing novel insights into the underlying mechanisms. Through simulations and experiments, a mapping relationship between the grinding force of a single abrasive grain and that of the grinding head was established. The research elucidates the mechanisms of phase transformation and grain size changes in the plastic deformation zone under mechanical-thermal interactions, thereby complementing the existing body of knowledge. Key findings include a quantitative analysis of sub-surface grain sizes, revealing that <i>γ</i>′ phase particles within the white layer are refined to approximately 21.2&#xa0;nm, while the minimum grain size in the heat-affected zone (HAZ) is reduced to 5.55&#xa0;μm, with an average grain size of 16.31&#xa0;μm, indicating significant grain refinement. The study also demonstrates that increasing the grinding head speed effectively mitigates surface layer damage, offering practical guidance for optimizing machining processes. Furthermore, the combined effects of phase transformation and grain refinement lead to a notable enhancement in material hardness, with hardness values within 40&#xa0;μm of the grinding surface increasing by 21.8-26.8% from an initial hardness of 430.83 HV. These findings provide valuable insights into the microstructural changes occurring during machining processes, advancing the understanding of material behavior under grinding conditions and offering implications for improving the performance and lifespan of components in critical applications.</p>

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Microstructural Evolution and Mechanical Behavior in Grinding-Induced Surface Layers of Nickel-Based Superalloys

  • 期刊论文

  • 发表日期：

    2025年9月25日

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  • Furong Wang,
  • Jingjie Zhang,
  • Guangchun Xiao,
  • Zhaoqiang Chen,
  • Hui Chen,
  • Chonghai Xu,
  • Mingdong Yi,
  • Qianqian Wang

摘要

Nickel-based superalloys are widely used in aerospace, automotive, and precision machinery due to their excellent properties. The microstructure and mechanical properties of machined surfaces critically affect component performance and lifespan. However, the mechanisms of microstructural changes (e.g., phase transformation and grain refinement) caused by mechanical-thermal coupling during grinding and their impact on material properties are not fully understood. This study investigates the effects of grinding on the microstructure and mechanical properties of machined surfaces, providing novel insights into the underlying mechanisms. Through simulations and experiments, a mapping relationship between the grinding force of a single abrasive grain and that of the grinding head was established. The research elucidates the mechanisms of phase transformation and grain size changes in the plastic deformation zone under mechanical-thermal interactions, thereby complementing the existing body of knowledge. Key findings include a quantitative analysis of sub-surface grain sizes, revealing that γ′ phase particles within the white layer are refined to approximately 21.2 nm, while the minimum grain size in the heat-affected zone (HAZ) is reduced to 5.55 μm, with an average grain size of 16.31 μm, indicating significant grain refinement. The study also demonstrates that increasing the grinding head speed effectively mitigates surface layer damage, offering practical guidance for optimizing machining processes. Furthermore, the combined effects of phase transformation and grain refinement lead to a notable enhancement in material hardness, with hardness values within 40 μm of the grinding surface increasing by 21.8-26.8% from an initial hardness of 430.83 HV. These findings provide valuable insights into the microstructural changes occurring during machining processes, advancing the understanding of material behavior under grinding conditions and offering implications for improving the performance and lifespan of components in critical applications.