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12 pages, 34805 KiB

Open AccessArticle

Investigation of Microstructure and Mechanical Properties of the Repaired Precipitation-Strengthened Ni-Based Superalloy via Laser Melting Deposition

by Wengao Yan, Beirao Xue, Jinjun Li, Minghuang Zhao and Xiangde Bian

Metals 2023, 13(12), 1957; https://doi.org/10.3390/met13121957 - 30 Nov 2023

Viewed by 1146

Abstract

In this study, a typical γ′ phase precipitation-strengthened Ni-based superalloy DZ411 was repaired using an LMD-based repairing technique with an IN738LC superalloy, and crack-free samples were acquired. The mechanical properties and microstructure of different areas inside the repair sample were investigated, including the [...] Read more.

In this study, a typical γ′ phase precipitation-strengthened Ni-based superalloy DZ411 was repaired using an LMD-based repairing technique with an IN738LC superalloy, and crack-free samples were acquired. The mechanical properties and microstructure of different areas inside the repair sample were investigated, including the IN738LC deposit, the DZ411 substrate, and the interface between these two parts. The differences in mechanical properties between different areas were explained via analyzing fractography and KAM maps. It was found that the coarse carbides of the DZ411 substrate might lead to rapid cracking of grain boundaries, resulting in the worst mechanical properties of the DZ411 substrate. The IN738LC deposit demonstrated significantly superior mechanical properties in comparison to the DZ411 substrate. Its tensile strength exceeded that of the substrate by over 250 MPa, while its relative elongation after fracture was twice as great as that of the substrate. The excellent mechanical properties of the IN738LC deposit could be attributed to its fine microstructure, which resisted rapid cracking and generated a large number of GNDs during the plastic deformation process. For the interface between the deposit and substrate, although its hardness before the tensile test was low, it could also generate many GNDs during the plastic deformation process, hence exhibiting commendable mechanical properties. The research results show that using an LMD-based repairing technique with IN738LC superalloy to repair γ′ phase precipitation-strengthened Ni-based superalloy DZ411 is a feasible solution. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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19 pages, 9190 KiB

Open AccessArticle

Structure and Properties Evolution of AZhK Superalloy Prepared by Laser Powder Bed Fusion Combined with Hot Isostatic Pressing and Heat Treatment

by Fedor A. Baskov, Zhanna A. Sentyurina, Pavel A. Loginov, Marina Ya. Bychkova, Ivan A. Logachev and Evgeny A. Levashov

Metals 2023, 13(8), 1397; https://doi.org/10.3390/met13081397 - 4 Aug 2023

Cited by 1 | Viewed by 979

Abstract

The structure and properties of samples obtained by the laser powder bed fusion (LPBF) method from the AZhK alloy, intended for the manufacture of heavily loaded body parts with operating temperatures up to 800 °C, have been studied. The optimal mode of LPBF, [...] Read more.

The structure and properties of samples obtained by the laser powder bed fusion (LPBF) method from the AZhK alloy, intended for the manufacture of heavily loaded body parts with operating temperatures up to 800 °C, have been studied. The optimal mode of LPBF, ensuring the attainment of the minimal residual porosity of 0.02%, was identified for the superalloy AZhK. Additionally, the evolution of the microstructure of LPBF samples after hot isostatic pressing (HIP) and heat treatment (HT) was studied using optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The macrostructure of LPBF samples is represented by columnar grains oriented in the direction of predominant heat dissipation, perpendicular to the build plate. At the microlevel, the structure consists of colonies of columnar dendrites. Nb₄AlC₃ and Nb₆C₄ carbides, as well as the Mo₂Hf Laves phase, are precipitated in the interdendritic region as a result of doping element segregation. The low strength of the LPBF samples (σ = 967 ± 10 MPa) is caused by the fact that there are no reinforcing particles and by high internal stress due to high crystallization speed. HIP and HT were found to have a favorable effect on the structure and properties of the LPBF samples. The post-treatment resulted in uniform distribution of γ′-phase precipitates sized up to 250 nm in the matrix bulk and carbides at grain boundaries, as well as Laves phase dissolution. Therefore, the strength characteristics were significantly improved: by 45% at room temperature and by 50% at elevated temperatures. High strength and ductility were attained (at 20 °C, σ²⁰ = 1396 ± 22 MPa and δ = 19.0 ± 3.0 %; at 650 °C, σ⁶⁵⁰ = 1240 ± 25 MPa and δ = 15.8 ± 1.5%; at 750 °C, σ⁷⁵⁰ = 1085 ± 23 MPa and δ = 9.1 ± 2.3%). An ejector-type part was fabricated, and its geometric parameters coincided with those in the electronic models. After conducting computed tomography, it was found that there are no defects in the form of non-fusion and microcracks within the volume of the part; however, it was observed that the pore size is ≥20 μm. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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12 pages, 58476 KiB

Open AccessArticle

Effect of Laser Power on the Recrystallization Temperature of an Additively Manufactured IN718

by Deuk Hyun Son, In Soo Kim, Baig-Gyu Choi, Jeonghyeon Do, Yoon Suk Choi and Joong Eun Jung

Metals 2023, 13(8), 1355; https://doi.org/10.3390/met13081355 - 28 Jul 2023

Viewed by 1380

Abstract

Over the past few decades, there has been much research on additive manufacturing in both the academic and the industrial spheres to overcome the limitations of conventional manufacturing methods, thereby enabling the production of complex designs for improved performance. To achieve this purpose, [...] Read more.

Over the past few decades, there has been much research on additive manufacturing in both the academic and the industrial spheres to overcome the limitations of conventional manufacturing methods, thereby enabling the production of complex designs for improved performance. To achieve this purpose, it is crucial to meticulously set suitable laser parameters within the context of microstructural characteristics, including type and fraction of defects, texture development, residual stress, and grain size, etc. In the present study, we focused on recrystallization behavior, a type of relaxation process for accumulated thermal stress during the L-PBF process, as a function of laser power applied on the L-PBF process. The laser power has significant effects on the amount of recrystallized grain, directly related to the recrystallization temperature. Within the range of laser power used in this study, a downward trend was observed in the recrystallization temperature as the laser power increased from 370 W to 390 W. This trend suggests that higher laser power leads to a faster cooling rate, influenced by the volume of melt pool as well as the amount of heat dissipation from the melt pool, resulting in higher thermal stress during the process. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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13 pages, 5952 KiB

Open AccessArticle

Microstructure and Mechanical Properties of Hastelloy X Fabricated Using Directed Energy Deposition

by Yoon-Sun Lee and Ji-Hyun Sung

Metals 2023, 13(5), 885; https://doi.org/10.3390/met13050885 - 3 May 2023

Cited by 4 | Viewed by 2945

Abstract

Laser-aided additive manufacturing is used for complex shapes and Ni-based superalloy parts. This study aimed to optimize the additive manufacturing process of Hastelloy X alloy to obtain its excellent mechanical properties without pores or cracks in the additively manufactured parts. The additively manufactured [...] Read more.

Laser-aided additive manufacturing is used for complex shapes and Ni-based superalloy parts. This study aimed to optimize the additive manufacturing process of Hastelloy X alloy to obtain its excellent mechanical properties without pores or cracks in the additively manufactured parts. The additively manufactured Hastelloy X was analyzed by comparing porosity, microstructure, and mechanical properties in as-built and post-heat treatment conditions. In addition, the pores existing inside the as-built specimen considerably decreased after the hot isostatic press (HIP) treatment. Furthermore, cell/columnar microstructures were observed owing to a fast cooling rate in the as-built condition. However, after heat treatment, dendrite structures disappeared, and recrystallized equiaxed grains were observed. The tensile test results showed that there was mechanical anisotropy along the vertical and horizontal directions, and as the microstructure changed to equiaxed grains after heat treatment, the mechanical anisotropy decreased, and the high-temperature properties improved. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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21 pages, 10774 KiB

Open AccessArticle

Hydrogen Embrittlement of Inconel 718 Manufactured by Laser Powder Bed Fusion Using Sustainable Feedstock: Effect of Heat Treatment and Microstructural Anisotropy

by Naveen Karuthodi Mohandas, Alex Giorgini, Matteo Vanazzi, Ton Riemslag, Sean Paul Scott and Vera Popovich

Metals 2023, 13(2), 418; https://doi.org/10.3390/met13020418 - 17 Feb 2023

Cited by 8 | Viewed by 3969

Abstract

This study investigated the in-situ gaseous (under 150 bar) hydrogen embrittlement behaviour of additively manufactured (AM) Inconel 718 produced from sustainable feedstock. Here, sustainable feedstock refers to the Inconel 718 powder produced by vacuum induction melting inert gas atomisation of failed printed parts [...] Read more.

This study investigated the in-situ gaseous (under 150 bar) hydrogen embrittlement behaviour of additively manufactured (AM) Inconel 718 produced from sustainable feedstock. Here, sustainable feedstock refers to the Inconel 718 powder produced by vacuum induction melting inert gas atomisation of failed printed parts or waste from CNC machining. All Inconel 718 samples, namely AM-as-processed, AM-heat-treated and conventional samples showed severe hydrogen embrittlement. Additionally, it was found that despite its higher yield strength (1462 ± 8 MPa) and the presence of δ phase, heat-treated AM Inconel 718 demonstrates 64% lower degree of hydrogen embrittlement compared to the wrought counterpart (Y.S. 1069 ± 4 MPa). This was linked to the anisotropic microstructure induced by the AM process, which was found to cause directional embrittlement unlike the wrought samples showing isotropic embrittlement. In conclusion, this study shows that AM Inconel 718 produced from recycled feedstock shows better hydrogen embrittlement resistance compared to the wrought sample. Furthermore, the unique anisotropic properties, seen in this study for Inconel 718 manufactured by laser powder bed fusion, could be considered further in component design to help minimise the degree of hydrogen embrittlement. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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11 pages, 7779 KiB

Open AccessArticle

Influence of Replacing Molybdenum with Tungsten on the Creep Fracture Property of Waspaloy Nickel-Based Alloy

by Hanxin Yao, Jianxin Dong, Zhihua Gong, Jiqing Zhao and Gang Yang

Metals 2022, 12(11), 1842; https://doi.org/10.3390/met12111842 - 28 Oct 2022

Cited by 2 | Viewed by 1607

Abstract

Alloys meeting the requirements of “700 °C and above” advanced ultra-super-critical technology, with higher thermal efficiency, have been developed in recent years. Here, a new wrought Ni-based superalloy with excellent high-temperature creep strength based on Waspaloy has been developed and is proposed as [...] Read more.

Alloys meeting the requirements of “700 °C and above” advanced ultra-super-critical technology, with higher thermal efficiency, have been developed in recent years. Here, a new wrought Ni-based superalloy with excellent high-temperature creep strength based on Waspaloy has been developed and is proposed as a candidate material for application in 700 °C class advanced ultra-super-critical steam turbine blades. In this new alloy, the Molybdenum (Mo) in Waspaloy is partially replaced by Tungsten (W). Creep tests have shown that this new Ni-based alloy has a 70 MPa higher creep-rupture strength than that of Waspaloy at 700 °C by extrapolating the experimental data. Detailed creep-rupture mechanisms have been analyzed by means of scanning electron microscopy, transmission electron microscopy, and chemical phase analysis with a view to devising potential approaches for performance improvements. The results showed that the partial replacement of Mo by W had negligible effect on the composition of carbides precipitated in the alloy. Instead, the amount of the γ′ phase was significantly increased, and mismatch between the γ and γ′ phases was reduced. In this way, the stability of the γ′ phase was increased, its coarsening rate was reduced, and its critical shear stress was increased. As a result, the high-temperature creep-fracture strength of the new alloy was increased. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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13 pages, 4508 KiB

Open AccessArticle

Mechanical Properties and Fracture Behavior of Laser Powder-Bed-Fused GH3536 Superalloy

by Haohan Ni, Qi Zeng, Kai Zhang, Yingbin Chen and Jiangwei Wang

Metals 2022, 12(7), 1165; https://doi.org/10.3390/met12071165 - 8 Jul 2022

Cited by 4 | Viewed by 2124

Abstract

Heat treatment (HT) is an important approach to tune the structure and mechanical properties of as-printed or hot-isostatic-pressed (HIPed) additive manufacturing materials. Due to the carbide precipitates extensively existing after HT with air cooling, this paper studies the microstructure and mechanical behavior of [...] Read more.

Heat treatment (HT) is an important approach to tune the structure and mechanical properties of as-printed or hot-isostatic-pressed (HIPed) additive manufacturing materials. Due to the carbide precipitates extensively existing after HT with air cooling, this paper studies the microstructure and mechanical behavior of laser powder-bed-fused (L-PBFed) GH3536 superalloy with laminar carbide precipitates at grain boundaries. By comparing with air-cooling samples and water-quenched samples, the results revealed that air cooling often introduced precipitates at grain boundaries, which impede the plastic deformation and are prone to lead to severe transgranular cracks on the fracture surface, contributing to a higher strain-hardening rate but lower ductility of HTed sample. Water quench can largely eliminate the grain-boundary precipitates, contributing to an optimized ductility even with smaller grain size. This work provides more details on the precipitate-deformation relation after HT. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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11 pages, 4895 KiB

Open AccessArticle

Laser Preheating for Hot Crack Reduction in Direct Metal Deposition of Inconel 738LC

by Fabian Soffel, Konrad Papis, Markus Bambach and Konrad Wegener

Metals 2022, 12(4), 614; https://doi.org/10.3390/met12040614 - 2 Apr 2022

Cited by 11 | Viewed by 3115

Abstract

Welding of precipitation-hardenable nickel-based super alloys that contain large amounts of Al and Ti is challenging due to their high susceptibility to hot cracking. For metal additive manufacturing (AM) by powder bed fusion (PBF) or direct metal deposition (DMD), various welding process adjustments [...] Read more.

Welding of precipitation-hardenable nickel-based super alloys that contain large amounts of Al and Ti is challenging due to their high susceptibility to hot cracking. For metal additive manufacturing (AM) by powder bed fusion (PBF) or direct metal deposition (DMD), various welding process adjustments may prevent the formation of cracks. The aim of this study is the development and experimental characterization of a laser preheating process for DMD of Inconel 738LC. Metallographic cross-sections of multiple test specimens were analyzed to quantify the effect of initial substrate temperature, specimen geometry, deposition parameters, and scanning strategy on the resulting crack density. The results show that increased substrate temperature by laser preheating and reduced specimen size leads to crack-free deposited structures. Therefore, the proposed preheating process may be applied for part fabrication or repair by DMD to reduce or even completely prevent the risk of hot cracking. Full article

(This article belongs to the Special Issue Additive Manufacturing of High Temperature Alloys)

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