{'fraction_non_alphanumeric': 0.021986353297952996, 'fraction_numerical': 0.008339651250947688, 'mean_word_length': 5.285714285714286, 'pattern_counts': {'":': 0, '<': 0, '<?xml version=': 0, '>': 0, 'https://': 0, 'lorem ipsum': 0, 'www.': 0, 'xml': 0}, 'pii_count': 0, 'substrings_counts': 0, 'word_list_counts': {'cursed_substrings.json': 0, 'profanity_word_list.json': 0, 'sexual_word_list.json': 0, 'zh_pornsignals.json': 0}}
An Investigation of Direct Powder Forging of Nickel Superalloy FGH96

Powder metallurgy (PM) nickel-based superalloy has been widely used in high temperature applications and is most commonly manufactured using hot isostatic pressing (HIP). However, HIP is an expensive process and takes a long time at high temperature which leads to the formation of networks of prior particle boundaries (PPBs). In this study, a recently developed processing method - direct powder forging (DPF) was employed to produce a PM nickel-based superalloy component, using a single acting hydraulic press under normal atmosphere. EBSD study has been conducted for its microstructure, grains size distribution, and grain boundary misorientation; and mechanical testing has been carried out for its hardness and tensile properties at room temperature and 650°C. It has been found that the DPFed material has reached full density in the whole component. Networks of PPBs have been broken in the direct powder forged FGH96 alloy. Compared with HIPed FGH96 alloy, the DPFed material has a substantially higher recystallisation nucleation degree and more recrystallised sub-grains. After heat treatment, the tensile properties of the direct powder forged FGH96 alloy match or surpass those of the material produced by HIP plus isothermal forging.