Abstract:
The rotary cold extrusion and non-rotary cold extrusion (spindle speed of 0) tests were conducted on deep hole in nickel-based superalloy plate with multi-stage convex hull carbide extrusion tool. The effects of extrusion rate (2.4%, 3.0%, 3.6%) and spindle speed (0,66,200 r·min
-1) on the surface integrity of the hole wall and fatigue life of the sample were studied, and the optimal rotary cold extrusion process was obtained. The results show that compared with those under non-rotary cold extrusion strengthening process, there were fewer micro-cracks on the surface of the hole wall after strengthened by rotary cold extrusion, and with increasing spindle speed, the micro-cracks and surface roughness increased; under the same spindle speed, the larger the extrusion rate, the smaller the roughness, the higher the surface hardness and the larger the residual compressive stress and compressive stress layer thickness. The optimized rotary cold extrusion process parameters were as following: spindle speed of 66 r·min
-1, extrusion rate of 3.0%. Under this process, the hole wall surface had fewer micro-cracks, thicker plastic deformation layer (about 30 μm), larger surface hardness (peak hardness of 515 HV), and lower surface roughness (
Ra of 0.298 μm); a circumferential residual compressive stress layer with a thickness of about 450 μm and a peak stress of 498 MPa was formed along the depth direction. The fatigue life of the samples after hole strengthening under the optimal process was about 6.6 times that of the unstrengthened samples, and the fatigue crack source was shifted from the surface of the hole wall to the interior by about 45 μm.