Avoiding cracks in additively manufactured non-weldable directionally solidified Ni-based superalloys

Dang, Xiaofeng; Li, Yao; Chen, Kai; Ramamurty, Upadrasta; Luo, Sihai; Liang, Xiaoqing; He, Weifeng

doi:10.1016/j.addma.2022.103095

Cited by 9 publications

(3 citation statements)

References 53 publications

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“…The susceptibility to cracking is mainly attributed to the high cooling rates and large thermal stresses inherently present in metal AM processes. In their investigative study, Dang et al [80] noted that hot cracking along grain boundaries was a prevalent issue in DED samples, induced by the constitutional liquation of segregated elements and the ensuing the formation of low-melting eutectics within interdendritic zones. Concurrently, solid-state cracking has also been identified as a significant concern in final AM parts.…”

Section: Cracking Defectsmentioning

confidence: 99%

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Zhang,

Xu,

et al. 2024

Crystals

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Directed Energy Deposition (DED), a branch of AM processes, has emerged as a significant technique for fabricating large metal components in sectors such as aerospace, automotive, and healthcare. DED is characterized by its high deposition rate and scalability, which stand out among other AM processes. However, it encounters critical issues such as residual stresses, distortion, porosity, and rough surfaces resulting from rapid melting and solidification. As a novel advancement, Ultrasonic-Assisted Directed Energy Deposition (UA-DED) integrates ultrasonic oscillations into DED aimed at addressing these challenges. Herein, the latest research related to the UA-DED process and the current major challenges of the DED process, residual stresses, porosity, and crack defects are critically reviewed. Subsequently, the paper also details the working principle and system components of UA-DED technology and reviews the material improvement by introducing UA into the DED process, grain, porosity, tensile properties, and deposition defects. The most critical optimization methods of process parameter variables for UA and the different material interaction mechanisms between UA and DED processes are identified and discussed in detail. Finally, the perspectives on the research gap and potential future developments in UA-DED are also discussed.

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Section: Cracking Defectsmentioning

confidence: 99%

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Zhang,

Xu,

et al. 2024

Crystals

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“…In addition, cracks are often found in the obtained materials in both PX shell and SX core. [69] Dang et al [71] simultaneously controlled solidification parameters (i.e., temperature gradient G, cooling rate at solid/liquid interface, and cooling rate of γ' solvus) in EB-based PBF study on IN 738 superalloy. A crack-free EB-PBF sample is obtained with maintained [001] fiber texture after post-print HT without inducing recrystallization.…”

Section: Influence Of Ded Process Parametersmentioning

confidence: 99%

Epitaxial Growth and Stray Grain Control toward Single‐Crystal Metallic Materials by Additive Manufacturing: A Review

Liu

Shi

2023

Adv Eng Mater

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Additive manufacturing (AM) possesses tremendous potential in controlling epitaxial growth of deposited materials, and thus attempts have been made to employ AM technology to fabricate or repair single‐crystal (SX) metal parts in recent years. One of the key issues in producing SX structures is the elimination of stray grain (SG) formation, but the layer‐wise fabrication nature of AM processes makes SGs difficult to avoid. Herein, the state‐of‐the‐art developments in this emerging research area are surveyed. It introduces the fundamental mechanisms of epitaxial growth in AM, summarizes the recent innovations and findings on using AM techniques to assist epitaxial growth and avoid SGs for SX metallic materials, discusses the relation of stray‐grain avoidance and crack‐free microstructure, and reviews the analytical and numerical modeling efforts for epitaxial growth and texture control. In addition, the challenges in achieving defect‐free SX microstructure are discussed, such that future research directions are pointed out. It is believed that this critical review provides insights on microstructure control for AM‐produced metallic materials and lays a solid foundation to stimulate more rigorous research.

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“…Another potential route to solve the problem of cracking is the optimization of the printing process. One of the most feasible strategies is to use induction heating to reduce the temperature gradient during the AM process [29][30][31]. However, the optimal printing parameters for different alloys are not evident.…”

Section: Introductionmentioning

confidence: 99%

Cracking Behavior of the ZhS6K Superalloy during Direct Laser Deposition with Induction Heating

Dmitrieva,

Semenyuk,

Klimova

et al. 2024

Metals

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For this work, the behavior of the ZhS6K alloy (Russian grade) in the process of direct laser deposition was investigated. Two samples, a “small” one (40 × 10 × 10 mm3) and “large” one (80 × 16 × 16 mm3), were fabricated with direct laser deposition. In both samples, the typical dual-phase γ/γ҆ microstructure with cuboidal shape of the γ҆ precipitates was observed. Both specimens revealed a similar tendency to continuous increasing in hardness from the bottom to the top associated with the refinement of γ҆ precipitates. The “small” sample was essentially crack-free, while the “large” one underwent extensive cracking. The possible effects of various factors, including thermal history, size, and shape of the gamma grains, on cracking behavior were discussed.

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Avoiding cracks in additively manufactured non-weldable directionally solidified Ni-based superalloys

Cited by 9 publications

References 53 publications

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Epitaxial Growth and Stray Grain Control toward Single‐Crystal Metallic Materials by Additive Manufacturing: A Review

Cracking Behavior of the ZhS6K Superalloy during Direct Laser Deposition with Induction Heating

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