Open Die Forging Simulation of Superalloy NIMONIC 115 Using DEFORM 3D Software Swarup Jana, Jyoti Mukhopadhyay, Rajashekar Rao, and Venkatesh Meka Abstract Nimonic 115 is a Ni-based superalloy that contains major alloying elements such as Cr, Co, and Mo. The alloy is used in the manufacturing of turbine blades for aerospace engines. The blades should have high fatigue strength and creep resistance at elevated temperature along with excellent wear and oxidation resis- tance properties. The presence of γ ′ phase with carbide precipitates in the γ phase matrix leads to high strength of Nimonic 115 even at high temperature. The product obtained either casting or powder metallurgy route needs to be thermo-mechanically processed to obtain the improved mechanical properties. Nimonic 115 has a very narrow working range with respect to temperature and strain rate. The reason may be due to the high phase stability of γ ′ phase at elevated temperature. During open die forging, Nimonic 115 is prone to surface defect, due to high local flow stress. In the present research work, the effect of heat transfer on deformation due to the transfer of billet from furnace to the forging setup has been examined. The combined effect of reduction and strain rate on the deformation has also been studied. Based on the simulation results using DEFORM 3D software, the optimum forging conditions have been estimated. Keywords NIMONIC 115 · DEFORM 3D · Simulation Introduction Nimonic 115 is a nickel (Ni)-based superalloy with major alloying elements such as Cr, Co, and Mo which is used for high-temperature applications. High strength, better creep resistance along with excellent wear and corrosion resistance properties at high temperature make Nimonic 115 suitable for its use in aerospace industry S. Jana · J. Mukhopadhyay (B ) IIT Gandhinagar, Gandhinagar, Gujarat 382355, India e-mail: jm@iitgn.ac.in R. Rao · V. Meka Mishra Dhatu Nigam Ltd, Hyderabad, Telangana 500058, India © The Minerals, Metals & Materials Society 2021 TMS 2021 150th Annual Meeting & Exhibition Supplemental Proceedings, The Minerals, Metals & Materials Series, https://doi.org/10.1007/978-3-030-65261-6_74 829