Effects of standard heat treatment on micro-to nanostructure heterogeneities in a Rene 65 Ni-based superalloy billet

Advancements in the manufacturing of aeroengine components with superior mechanical properties rely on the microstructure homogeneity of industrially forged Ni-based superalloys. Billets often contain microstructural heterogeneities that can persist throughout the process, potentially compromising the integrity of the final product. Rene 65 is a relatively new superalloy with high-temperature mechanical properties superior to those of Alloy 718. However, systematic studies on its microstructure-property relationships are scarce. Here, we correlate the microstructural evolution with the hardness of a Rene 65 billet subjected to industrial processing and standard heat treatments. Multiscale microstructural heterogeneities, including grain size, geometrically necessary dislocations, twin boundary density, and the multimodal distribution of γʹ precipitates, are characterised. Grain growth occurs near the billet centre. Precipitation varies with radial position, showing up to a two-fold change in primary and secondary γʹ fractions. Tertiary γʹ precipitates exhibit variations in morphology and chemical composition, with Cr and Co enrichment near the billet surface. These heterogeneities arise from varying strain distributions and cooling rates during radial forging. Sub-solvus annealing and ageing are shown to mitigate these heterogeneities by promoting recrystallisation, recovery, and homogeneous precipitation of tertiary γʹ. A strengthening model elucidates the active mechanisms in as-received and heat-tread conditions, predicting hardness with a deviation of <8 %. Analyses of grain boundaries and γ/γʹ interfaces reveal strong segregation of Mo, W, Nb, C and B before and after heat treatment, with Mo and B showing the highest interfacial excess values. Insights into the microstructural evolution and its impact on properties could guide the development of next-generation aerospace parts.