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Processing maps are key to guiding the thermo-mechanical processing (TMP) ofsuperalloys. However, traditional processing maps are incapable of delimitingfailure, which is an essential factor to be concerned about during the TMP ofsuperalloys. Employing isothermal hot compression experiments and finiteelement analysis (FEA), the present study examined the failure behaviors of apowder metallurgy (P/M) Ni-based superalloy and constructed processing mapswith failure domains based on the predicted failure threshold. Themicromechanical Gurson-Tvergaard-Needleman (GTN) damage model was employed inthe FEA to model the cavity-driven intergranular fracture of the superalloy.Deformation temperature and strain rate were considered in the range of 1050 ~1150 C and 0.001 ~ 1 s-1, respectively. The FEA results reveal that the maximumtensile stress locates at the outer budging surfaces of the samples, whichcauses failure initiation and subsequent propagation into longitudinal cracks,being consistent with the experiments. It is further demonstrated that thefailure is strain-controlled and the critical failure strain remains nearlyinsensitive to the range of strain rates considered while increasing with theincrease of temperature in a third-order polynomial. Finally, an optimizedprocessing window for hot deformation of the superalloy is formulated towarrant good hot workability while avoiding flow instability and failure. Thepresent study offers direct insights into the failure behaviors of P/M Ni-basedsuperalloys and details a modeling strategy to delineate optimized parametricspaces for the TMP of superalloys.

Failure behaviors and processing maps with failure domains for hot compression of a powder metallurgy Ni-based superalloy