Inconel 718 single and multipass modelling of hot forging

A better understanding of the competition between several mechanisms (dynamic recovery, dynamic recrystallization and plasticity hardening) is crucial for aircraft engine manufacturers. The aim of this paper is to improve the microstructure and therefore the mechanical properties of a nickel based superalloy used for rotating forged pieces. A nickel superalloy microstructure is the result of several successive hot forging processes: multipass processes, with intermediate dwell time and quenching. In this paper, an original three dimensional approach able to simulate these processes is proposed. The specific role of the different steps of the processes is analysed. In this approach, several forging thermo-mechanical parameters are taken into account: the working temperature, the strain rate, the final strain, the interpass time, etc. At high forging temperature, the studied INCONEL 718 presents an austenitic matrix γ (face centred cubic) assumed to be in a single phase. This approach proposes a sequential coupling of two models, one devoted to deformation and the other to recrystallization. Such a coupling enables the estimation of the effect of deformation and of different recrystallization types on mechanical behaviour and on micro-structural evolution. The approach is performed at the grain scale and takes into account the whole thermo-mechanical cycle with a focus on the dynamic behaviour. The first polycrystalline model is based on the plasticity mechanisms at the grains scale. The framework corresponds to finite transformations (large lattice rotations and small elastic strains). The model is implemented in ABACUS and CAST3M finite element codes. The second model is based on the recrystallization theory and uses a 3D cellular automaton. It describes dynamic recrystallization phenomena such as nucleation-growth and static or post-dynamic recrystallization. Such recrystallization mechanisms were observed during interpass time or during the successive heatings depending on the thermo-mechanical paths used in multipass forging. Dislocation densities are the internal variables common to the two models. The simulations are performed on a 3D Representative Elementary Volume (aggregate) obtained from Electron Back Scattering mapping. Numerical results are compared to experimental microstructures.