Ni-based superalloy as a potential tool material for thixoforming of steels

Semisolid processing, already a well established manufacturing route for the production of intricate, thin walled aluminium and magnesium parts with mechanical properties as good as forged grades, faces a major challenge in the case of steels. The tool materials must withstand complex load profiles and relatively higher forming temperatures for thousands of forming cycles for this near-net shape process to be attractive for steels on an industrial scale. The potential of a Ni-based superalloy, Inconel 617, reported to exhibit superior thermal fatigue resistance in demanding tooling applications, was investigated. The response to thermal cycling of this alloy at high temperatures was compared with that of X38CrMoV5 hot work tool steel widely used in the manufacture of conventional forging dies. The favourable thermophysical properties of the latter were completely negated by its limited temper resistance, while the Inconel 617 alloy responded to thermal cycling by the usual heat cracking mechanism.