Open Die Forging Simulation of Superalloy NIMONIC 115 Using DEFORM 3D Software

Nimonic 115 is a Ni-based superalloy that contains major alloying elements such as Cr, Co, and Mo. The alloy is used in the manufacturing of turbine blades for aerospace engines. The blades should have high fatigue strength and creep resistance at elevated temperature along with excellent wear and oxidation resistance properties. The presence of γ′ phase with carbide precipitates in the γ phase matrix leads to high strength of Nimonic 115 even at high temperature. The product obtained either casting or powder metallurgy route needs to be thermo-mechanically processed to obtain the improved mechanical properties. Nimonic 115 has a very narrow working range with respect to temperature and strain rate. The reason may be due to the high phase stability of γ′ phase at elevated temperature. During open die forging, Nimonic 115 is prone to surface defect, due to high local flow stress. In the present research work, the effect of heat transfer on deformation due to the transfer of billet from furnace to the forging setup has been examined. The combined effect of reduction and strain rate on the deformation has also been studied. Based on the simulation results using DEFORM 3D software, the optimum forging conditions have been estimated.