Material Health of NiCrBSi Alloy Parts Produced via the Laser Powder Bed Fusion Process
Abstract
:1. Introduction
2. Materials and Methods
2.1. Material
2.2. LPB-F Production
- Standard L-PBF productions (Figure 2) were carried out using a Renishaw AM400 with a standard baseplate (250 × 250 mm) heated to 170 °C. A laser power of 150, 175, 200, and 225 W is used. Various exposure times between 20 and 140 µs and point distances between 20 and 140 µm are tested. According to several papers in the field of nickel-based superalloys produced with a Renishaw AM400 device [53,54,55,56,57,58,59], parameter sets leading to a linear energy lower than 0.15 J·mm−1 and greater than 0.35 J·mm−1 and a VED greater than 130 J·mm−3 are not tested. Finally, the hatch distance was kept at 70 µm, except for the four samples obtained with an Hd between 50 and 110 µm. In total, 75 samples (cubes of 13 × 14 × 15 mm3) out of 76 were built (Figure 2a,c).
- High-temperature L-PBF production and laser remelting exploration were conducted with a modified SLM Solution 250 device (continuous laser) on a small round baseplate (100 mm diameter). Two preheating temperatures were tested: 300 and 500 °C. For 300 °C (Figure 2), a laser power of 100 and 150 W was used, and the laser scanning speed varied between 450 and 800 mm·s−1. Hatch spacing was kept at 70 µm. In total, 8 out of 16 samples (cubes of 10 × 10 × 10 mm3) were built (Figure 2b,d).
- For 500 °C (Figure 2), according to results obtained at 300 °C, a laser power of 100 W was mainly used with a laser speed between 100 and 1200 mm·s−1. A laser power of 150 W and laser speed of 600 mm·s−1 were also tested. Hatch spacing varied from 30 to 110 µm for four samples, and it was kept at 70 µm for the rest of the production. In total, 19 out of 20 samples (cubes of 10 × 10 × 10 mm3) were built (Figure 2b,d)).
- Finally, four samples were produced with laser remelting (same parameters as the first laser path) on a baseplate preheated at 500 °C. Two samples were obtained with a laser power of 100 W, a laser speed of 200 mm·s−1, and a hatch spacing of 30 and 110 µm. Two other samples were constructed with a laser power of 150 W, a laser speed of 600 mm·s−1, and a hatch spacing of 30 and 110 µm. In total, 3 out of 4 samples (cubes of 10 × 10 × 10 mm3) were built. Those parameter sets are chosen for their capacity to produce a few cracks (Figure 2b,d)).
2.3. Sample Preparation
2.4. Defects Detection and Analysis
2.5. Defects Quantification
3. Results
3.1. Processability
3.2. Material Health
3.2.1. Qualitative Defect Analysis
3.2.2. Quantitative Defect Analysis
4. Discussion
4.1. Processability
4.2. Lack of Fusion
4.3. Cracks
4.4. Process Optimization
5. Conclusions
- Given that circular objects with a coarse microstructure are frequently observed with a lack of fusion, powder bed screening due to spatters emerging from the melting pool is the reason for the large lack of fusion;
- Preheating the baseplate up to 500 °C reduces the surface fraction of areas with a lack of fusion to less than 1%;
- Given the brittle fracture surface, cracking is most likely to occur in a solid state;
- Preheating the baseplate up to 500 °C generates widely spaced, shorter, and wider cracks due to the sample’s softening and/or thermal gradient reduction.
- The wide cracks concentrated at the sample’s corners might engender catastrophic flacking after sample preparation or under load;
- Process parameters set at a laser power of 150 W, a laser scanning speed of 732 mm·s−1, a hatch spacing of 70 µm, and a preheating temperature of 170 °C show a good compromise for obtaining a surface density of 98%, with narrow cracks that are 11 µm wide, while limiting the crack’s length per unit of area to 4 ± 0.4 mm.mm−2.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Elements | Ni | Cr | B | Si | Fe | C | O |
---|---|---|---|---|---|---|---|
D60 Bal. | Bal. | 14 | 3.5 | 3.9 | 3.1 | 0.63 | 0.012 |
P (W) | v (mm·s−1) | Hs (µm) | Preheat (°C) | Surface Density (%) | Crack Width (µm) | Crack Length (mm·mm−2) |
---|---|---|---|---|---|---|
150 | 833 | 70 | 170 | 98 ± 1 | 12 ± 2 | 3.7 ± 0.7 |
150 | 732 | 70 | 170 | 98 ± 1 | 11 ± 1 | 4.0 ± 0.4 |
200 | 1000 | 50 | 170 | 98 ± 1 | 12 ± 1 | 3.1 ± 0.4 |
100 | 550 | 70 | 300 | 98 ± 2 | 15 ± 3 | 2.3 ± 0.4 |
100 | 200 | 70 | 500 | 98 ± 2 | 24 ± 11 | 0.6 ± 0.3 |
100 | 300 | 70 | 500 | 99 ± 1 | 19 ± 5 | 1.1 ± 0.3 |
100 | 750 | 70 | 500 | 99 ± 1 | 19 ± 6 | 1.1 ± 0.5 |
100 | 200 | 30 | 500 | 99 ± 1 | 28 ± 9 | 0.9 ± 0.4 |
100 * | 200 | 30 | 500 | 98 ± 2 | 18 ± 6 | 0.8 ± 0.3 |
100 * | 200 | 110 | 500 | 99 ± 1 | 19 ± 9 | 0.8 ± 0.6 |
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Ty, A.; Balcaen, Y.; Mokhtari, M.; Rigaud, J.; Dalverny, O.; Alexis, J. Material Health of NiCrBSi Alloy Parts Produced via the Laser Powder Bed Fusion Process. Metals 2023, 13, 1669. https://doi.org/10.3390/met13101669
Ty A, Balcaen Y, Mokhtari M, Rigaud J, Dalverny O, Alexis J. Material Health of NiCrBSi Alloy Parts Produced via the Laser Powder Bed Fusion Process. Metals. 2023; 13(10):1669. https://doi.org/10.3390/met13101669
Chicago/Turabian StyleTy, Anthony, Yannick Balcaen, Morgane Mokhtari, Jordan Rigaud, Olivier Dalverny, and Joël Alexis. 2023. "Material Health of NiCrBSi Alloy Parts Produced via the Laser Powder Bed Fusion Process" Metals 13, no. 10: 1669. https://doi.org/10.3390/met13101669