International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

This study evaluates the applicability of Powder Forging for producing hypercompositional structures from heat-resistant powders based on Inconel 625, ZhS6U, and CoCrAlY alloys. One-step forging and triple forging at 1150 °C were examined to determine their influence on densification, prior particle boundary elimination, microstructural evolution, and high-temperature mechanical behaviour. Triple forging markedly improved interparticle bonding, reduced structural defects, and enabled the formation of dense composite architectures with statistically distributed constituents. The Inconel 625-ZhS6U and Inconel 625-CoCrAlY systems demonstrated high yield strength over a broad temperature range and exhibited anomalous strengthening at elevated temperatures, attributed to dynamic strain aging and phase redistribution. The results confirm that Powder Forging is a promising thermomechanical route for designing advanced heat-resistant powder composites for aerospace hot-section applications.

This study investigates the compaction and deformation behavior of Inconel 625 powder using direct powder forging at temperatures of 950 °C and 1150 °C. Finite element modeling was conducted and validated with experimental data. The residual porosity after deformation was 6.5% at 950 °C and 2% at 1150 °C. Samples forged at 1150 °C demonstrated superior mechanical properties, including a bending strength of 1750 MPa and fracture toughness of 42 MPa·m¹ᐟ². In contrast, lower temperature deformation resulted in poorer grain boundary quality and reduced mechanical performance. Post-deformation annealing at 950 °C enhanced microstructural integrity through recrystallization, improving strength to 1540 MPa and toughness to 30.9 MPa·m¹ᐟ². Flow stress at 700 °C ranged from 450 to 650 MPa, confirming the material’s suitability for high-temperature aerospace applications. The findings indicate that 1150 °C is the optimal forging temperature for producing dense, high-strength components from Inconel 625 powder.