Abnormal flow behavior and necklace microstructure of powder metallurgy superalloys with previous particle boundaries (PPBs)

Powder metallurgy (P/M) has been introduced as an innovative process to manufacture high performance components with fine, homogenous and segregation-free microstructure. Unfortunately, previous particle boundary (PPB) precipitated during the powder metallurgy process. Since undesirable PPB is detrimental to mechanical properties, hot extrusion or/and isothermal forging are needed. In present research, isothermal compression tests were conducted on P/M FGH4096 superalloys with typical PPBs. Abnormal flow behavior during high-speed deformation has been quantitatively investigated. Caused by the competition mechanism between work-hardening and dynamic-softening, abnormal flow behaves typical four stages (viz., work-hardening, stable, softening and steady). Microstructure observation for hardening or/and softening mechanism has been investigated. Meanwhile, necklace microstructure was observed by scanning electron microscope, and the grain fraction analysis was performed by using electron backscatter diffraction. Transmission electron microscopy was used for characterizing the boundary structure. Necklace microstructural mechanism for processing P/M superalloys has been developed, and the dynamic recrystallization model has also been conducted. Bulge–corrugation model is the primary nucleation mechanism for P/M superalloys with PPBs. When PPB is entirely covered with new grains, necklace microstructure has formed. Bulge–corrugation mechanism can repeatedly take place in the following necklace DRX.