Deformation characteristics and performance evolution of superalloy capillary drawn by electrically assisted microforming

• Electroplastic effects on surface quality and geometries during EA microforming are studies. • Grain deformability and recrystallization are related to the electroplastic mechanisms. • The relationship between current parameters and performance evolution is presented. • An EA microforming process chain for capillaries is proposed and optimized. • The overall performance of EA manufactured capillaries is evaluated. Thin-walled superalloy capillaries are considered the core components of the heat exchanger in the hypersonic vehicle. To achieve the precise and efficient fabrication of capillaries, this study proposes an electrically assisted (EA) microforming process and investigates the deformation characteristics and performance evolution of capillaries under electric current. Experimental results show the EA drawing at 600 °C enhances the grain coordinated deformation capacity and dislocation recovery, while the ultrafast complete recrystallization and gradient grain microstructure are achieved by the EA annealing above 800 °C for 15 s. The microstructural evolution improves ductility and avoids macro defects, which is related to the reduction of activation energy of dislocation and grain boundary motion under the electroplastic mechanisms. In addition, the inhibition of the electric current on the increase in wall thickness is attributed to the increase in friction coefficient and the shedding of the oxide layer, while the electric current improves surface quality by forming ultrafine grains, oxidizing peaks, and healing troughs. Compared with the conventional manufactured capillaries, the surface quality, tensile strength, and elongation of the EA manufactured capillaries with the size of φ0.9 mm × 58 μm are increased by 129.0%, 31.1%, and 9.4%, respectively. A heat exchanger module integrated by the EA manufactured capillaries can cool the 25 m/s airflow from 1000 °C to 672 °C within 1 ms