Influence of powder characteristics on microstructure and mechanical properties of Inconel 718 superalloy manufactured by direct energy deposition

Wang, Zhen; Wang, Jiang; Xu, Shurong; Liu, Bo; Sui, Qingxuan; Zhao, Fengjun; Gong, Lian; Liu, Jun

doi:10.1016/j.apsusc.2022.152545

Cited by 21 publications

(4 citation statements)

References 20 publications

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“…This assumption was strongly supported by the relatively brittle fatigue fracture of WLAM 316L, which demonstrated the intensifying effect of intralayer porosity on internal cracking, along with reduced load bearing. This insight is in line with the results of Solberg et al [ 30 ], Wang et al [ 56 ], and Sheridan et al [ 57 ], who found a clear link between the reduced fatigue endurance of and the presence of porosity in stainless steel and superalloys produces by an AM process. In corrosion fatigue conditions, the comparatively reduced fatigue endurance of WLAM 316L can be mainly related to the relatively increased pitting corrosion attack that enhanced crack initiation processes [ 58 ].…”

Section: Discussionsupporting

confidence: 90%

The Influence of Intralayer Porosity and Phase Transition on Corrosion Fatigue of Additively Manufactured 316L Stainless Steel Obtained by Direct Energy Deposition Process

et al. 2022

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A direct energy deposition (DED) process using wires is considered an additive manufacturing technology that can produce large components at an affordable cost. However, the high deposition rate of the DED process is usually accompanied by poor surface quality and inherent printing defects. These imperfections can have a detrimental effect on fatigue endurance and corrosion fatigue resistance. The aim of this study was to evaluate the critical effect of phase transition and printing defects on the corrosion fatigue behavior of 316L stainless steel produced by a wire laser additive manufacturing (WLAM) process. For comparison, a standard AISI 316L stainless steel with a regular austenitic microstructure was studied as a counterpart alloy. The structural assessment of printing defects was performed using a three-dimensional non-destructive method in the form of X-ray microtomography (CT) analysis. The microstructure was evaluated by optical and scanning electron microscopy, while general electrochemical characteristics and corrosion performance were assessed by cyclic potentiodynamic polarization (CCP) analysis and immersion tests. The fatigue endurance in air and in a simulated corrosive environment was examined using a rotating fatigue setup. The obtained results clearly demonstrate the inferior corrosion fatigue endurance of the 316L alloy produced by the WLAM process compared to its AISI counterpart alloy. This was mainly related to the drawbacks of WLAM alloys in terms of having a duplex microstructure (austenitic matrix and secondary delta-ferrite phase), reduced passivity, and a significantly increased amount of intralayer porosity that acts as a stress intensifier of fatigue cracking.

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Section: Discussionsupporting

confidence: 90%

The Influence of Intralayer Porosity and Phase Transition on Corrosion Fatigue of Additively Manufactured 316L Stainless Steel Obtained by Direct Energy Deposition Process

et al. 2022

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“…Studies have shown that PREP powders with less porosity and dilution meaning better printing quality in comparison to GA powders. Also, PREP powders had lower Nb segregation and lower Laves phase fraction resulting in better overall mechanical properties [77][78][79].…”

Section: Metal Alloys or Metallic Compositesmentioning

confidence: 99%

“…Chen et al [115] made a comparison of nickel-based PREP-produced powders with GA powders, finding a recrystallization degree is higher in GA powders leading to lesser printing quality. Also, studies have shown that PREP as a process for recycling powders led to particles having a smoother surface, better microstructure and a reduced percentage of broken particles in the exported powder in comparison to the conventional GA process [77,78] as shown clearly in Figure 5.…”

Section: Metal Additive Manufacturingmentioning

confidence: 99%

Mechanical Performance of Recycled 3D Printed Sustainable Polymer-Based Composites: A Literature Review

Kyriakidis,

Kladovasilakis,

Pechlivani

et al. 2024

J. Compos. Sci.

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The development of efficient waste valorization strategies has emerged as an important field in the overall efforts for alignment with the environmental goals that have been set by the European Union (EU) Green Deal regarding the development of sustainable circular economy models. Additive manufacturing has emerged as a sustainable method for secondary life product development with the main advantages of it being a form of net-zero waste production and having the ability to successfully transport complex design to actual products finding applications in the industry for rapid prototyping or for tailored products. The insertion of eco-friendly sustainable materials in these processes can lead to significant reduction in material footprints and lower energy demands for the manufacturing process, helping achieve Sustainable Development Goal 12 (SDG12) set by the EU for responsible production and consumption. The aim of this comprehensive review is to state the existing progress regarding the incorporation of sustainable polymeric composite materials in additive manufacturing (AM) processes and identify possible gaps for further research. In this context, a comprehensive presentation of the reacquired materials coming from urban and industrial waste valorization processes and that are used to produce sustainable composites is made. Then, an assessment of the printability and the mechanical response of the constructed composites is made, by taking into consideration some key thermal, rheological and mechanical properties (e.g., viscosity, melting and degradation temperature, tensile and impact strength). Finally, existing life cycle analysis results are presented regarding overall energy demands and environmental footprint during the waste-to-feedstock and the manufacturing processes. A lack of scientific research was observed, regarding the manifestation of novel evaluation techniques such as dynamic mechanical analysis and impact testing. Assessing the dynamic response is vital for evaluating whether these types of composites are adequate for upscaling and use in real life applications.

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“…Inconel 718 is widely used in the aerospace, automotive and energy industries such as manufacturing of aeroengine turbine blades, turbine disks, and engine combustion chambers due to their good high temperature strength, fatigue performance creep, and rupture strength, oxidation resistance, and thermal corrosion resistance up to 700 •C [1,4,19,20,[42][43][44]. Inconel 718, strengthened by the ordered D022 body-centered tetragonal phase of γ″ (Ni3Nb) and ordered L12 intermetallic phase of γ′ (Ni3(Al, Ti)) [45,46].It has high strength and hardness because of solid-solution hardening, carbide strengthening, and precipitation hardening, as well as good corrosion resistance due to the addition of chromium [47].…”

Section: Introductionmentioning

confidence: 99%

Effect of Process Parameters on the Geometry of Single-Track Deposits of Inconel 718 onto AISI4140 Using Laser Cladding

momeni,

Coelho,

Nuñez

et al. 2024

Preprint

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AISI 4140 alloy steel finds extensive applications in industrial settings such as gears and blades owing to its exceptional combination of high strength and ductility. However, prolonged exposure to harsh operating conditions can result in significant mechanical failures, necessitating essential repair techniques to restore functionality and preserve the substantial value of these components. Among the various repair methods, directed energy deposition, an additive manufacturing technique, is gaining prominence for its efficacy in producing and restoring mechanically stressed components. Compared to traditional welding methods and metal spraying, laser cladding offers advantages such as reduced heat input and minimal dilution, resulting in superior metallurgical bonds. This research focuses on depositing Inconel 718 on AISI 4140 substrate using the laser cladding technique to evaluate the feasibility of this alloy for repairing AISI 4140 components. The investigation explores the influence of key laser cladding parameters, including laser power, scanning speed, and mass flow rate, on critical attributes of deposited beads such as width, height, clad angle, and dilution ratio. The results elucidate the effects of varying parameters: increasing scanning speed reduces bead dimensions and clad angle while increasing dilution. Elevating the powder-feeding rate increases bead height and wetting angle, with minimal impact on width and decreased dilution. Augmenting laser power increases bead width and reduces wetting angle, with dilution showing minimal change. Based on the findings, the optimal process parameters for future investigations are identified as a laser power of 950W, a laser scan speed of 300mm/min, and a mass flow rate of 4.31 g/min. Furthermore, the research demonstrates commendable metallurgical bonding at the interface between the two dissimilar materials, affirming the feasibility of integrating them through laser cladding.

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Influence of powder characteristics on microstructure and mechanical properties of Inconel 718 superalloy manufactured by direct energy deposition

Cited by 21 publications

References 20 publications

The Influence of Intralayer Porosity and Phase Transition on Corrosion Fatigue of Additively Manufactured 316L Stainless Steel Obtained by Direct Energy Deposition Process

The Influence of Intralayer Porosity and Phase Transition on Corrosion Fatigue of Additively Manufactured 316L Stainless Steel Obtained by Direct Energy Deposition Process

Mechanical Performance of Recycled 3D Printed Sustainable Polymer-Based Composites: A Literature Review

Effect of Process Parameters on the Geometry of Single-Track Deposits of Inconel 718 onto AISI4140 Using Laser Cladding

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