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<p>Nickel-based single crystal superalloys (NBSXs) are widely utilized as crucial components in the aerospace industry owing to their absence of grain boundaries and exceptional high-temperature resistance. Consequently, it is crucial to explore how their remarkable crystal orientation anisotropy can be leveraged to enhance machined surface quality and mitigate subsurface defects, ultimately extending the useful life of the workpiece. In this paper, we have constructed four typical microscopic models of NBSXs with distinct crystal orientations using a molecular dynamics approach. At the microscopic atomic level, we analyzed the distribution of subsurface dislocation lines, defective atoms, and crystal defects in NBSXs with various crystal orientations after the grinding process. The dislocation slip fracture mechanisms of NBSXs at different crystal planes were examined using the Peierls-Nabarro stress. The results indicate that NBSXs are more susceptible to dislocation slip and exhibit a more profound impact on the subsurface in the (111)[<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(1\overline{1}0]\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mn>1</mn> <mover> <mn>1</mn> <mo>¯</mo> </mover> <mrow> <mn>0</mn> <mo stretchy="false">]</mo> </mrow> </mrow> </math></EquationSource> </InlineEquation> grinding direction. Conversely, they encounter greater difficulty in dislocation slip, display less distribution of dislocation lines, and exhibit reduced diffusion of crystal defects to the subsurface in the (011)[0<InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\overline{1}\)</EquationSource> <EquationSource Format="MATHML"><math> <mover> <mn>1</mn> <mo>¯</mo> </mover> </math></EquationSource> </InlineEquation>1] grinding direction. The simulation results align well with the theoretical calculations and analyses. The findings of this study can serve as a theoretical reference for optimizing grinding process parameters and fostering material innovation.</p>

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The Effect of Anisotropy on the Evolution of Subsurface Defects in Nickel-Based Single Crystal Superalloy Grinding at the Atomic Scale

  • 期刊论文

  • 发表日期：

    2025年10月1日

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  • Fang Yu,
  • Jiachun Li

摘要

Nickel-based single crystal superalloys (NBSXs) are widely utilized as crucial components in the aerospace industry owing to their absence of grain boundaries and exceptional high-temperature resistance. Consequently, it is crucial to explore how their remarkable crystal orientation anisotropy can be leveraged to enhance machined surface quality and mitigate subsurface defects, ultimately extending the useful life of the workpiece. In this paper, we have constructed four typical microscopic models of NBSXs with distinct crystal orientations using a molecular dynamics approach. At the microscopic atomic level, we analyzed the distribution of subsurface dislocation lines, defective atoms, and crystal defects in NBSXs with various crystal orientations after the grinding process. The dislocation slip fracture mechanisms of NBSXs at different crystal planes were examined using the Peierls-Nabarro stress. The results indicate that NBSXs are more susceptible to dislocation slip and exhibit a more profound impact on the subsurface in the (111)[ \(1\overline{1}0]\) 1 1 ¯ 0 ] grinding direction. Conversely, they encounter greater difficulty in dislocation slip, display less distribution of dislocation lines, and exhibit reduced diffusion of crystal defects to the subsurface in the (011)[0 \(\overline{1}\) 1 ¯ 1] grinding direction. The simulation results align well with the theoretical calculations and analyses. The findings of this study can serve as a theoretical reference for optimizing grinding process parameters and fostering material innovation.