Introduction to Common Production Processes of Nickel-Based Alloys

Nickel-based alloys are widely used in aerospace, chemical processing, energy, and marine engineering due to their excellent high-temperature strength, corrosion resistance, and good workability. To ensure their superior performance, several advanced production processes are commonly adopted. The following are some of the most frequently used methods:

1. Vacuum Induction Melting (VIM)

• Principle: Melts raw materials by electromagnetic induction under vacuum conditions.
• Advantages: Effectively removes gaseous impurities, prevents oxidation and nitridation, and improves alloy purity.
• Applications: Used for the initial melting of high-performance nickel-based alloys, especially in aerospace engines and nuclear materials.

2. Vacuum Arc Remelting (VAR)

• Principle: The alloy, in the form of an electrode, is remelted under vacuum by an electric arc, then resolidified.
• Advantages: Reduces segregation, improves structural uniformity, and enhances mechanical properties.
• Applications: Often combined with VIM, widely applied to key load-bearing components such as turbine blades and aerospace parts.

3. Powder Metallurgy (PM)

• Principle: Produces alloy powders, then forms materials through hot isostatic pressing (HIP) or powder sintering.
• Advantages: Ensures uniform microstructure, enables the production of complex shapes, and avoids casting defects such as shrinkage cavities.
• Applications: Extensively used in 3D printing and the manufacturing of complex components.

4. Vacuum Induction Melting + Electroslag Remelting (VIM + ESR)

• Principle: Alloys are first purified by VIM, then refined through electroslag remelting to improve chemical homogeneity.
• Advantages: Further reduces inclusions, minimizes segregation, and enhances toughness and fatigue resistance.
• Applications: Applied in industries where extremely high purity and stability are required, such as nuclear power and high-end chemical equipment.

Conclusion

Nickel-based alloys can be produced through various processes, each significantly influencing purity, microstructure, and performance. Methods such as VIM, VAR, PM, ESR, and single-crystal technology complement each other, enabling nickel-based alloys to withstand extreme working conditions. With continuous technological advancements, the production of nickel-based alloys will become more refined and intelligent in the future.