Mechanical Performance of a Non-weldable Ni-Base Superalloy: Inconel 738 Fabricated by Electron Beam Melting

Kirka, Michael M.; Fernandez-Zelaia, Patxi; Lee, Yousub; Nandwana, Peeyush; Yoder, Sean; Acevedo, Obed D.; Ryan, Daniel P.

doi:10.1007/978-3-030-51834-9_105

Cited by 11 publications

(4 citation statements)

References 39 publications

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“…Often, when attempting to use new materials, difficulties arise due to the formation of various defects. In particular, heat-resistant nickel alloys with an increased γ' phase content pose challenges in additive manufacturing [2,7,8]. Cracks frequently appear in the structure of samples due to the formation of significant temperature gradients during high-energy laser or electron beam processing, as well as the low material elongation values [2,[7][8][9][10].…”

Section: Introductionmentioning

confidence: 99%

“…In particular, heat-resistant nickel alloys with an increased γ' phase content pose challenges in additive manufacturing [2,7,8]. Cracks frequently appear in the structure of samples due to the formation of significant temperature gradients during high-energy laser or electron beam processing, as well as the low material elongation values [2,[7][8][9][10]. The low weldability and the complexity of the chemical composition of alloys also contribute to the formation of hot cracks and high porosity in materials.…”

Section: Introductionmentioning

confidence: 99%

“…Research into ways to prevent the occurrence of such defects is an important direction that will expand the range of materials and ensure the required properties in products. Several studies have investigated the formation and reduction of defects [2,[7][8][9][11][12][13]. It has been found that one of the main causes of defect formation in the form of cracks is the segregation of alloy components and their precipitation at grain boundaries, as well as the formation of shrinkage voids [2,13].…”

Section: Introductionmentioning

confidence: 99%

“…These parameters affect the distribution of stresses that occur during material melting. The ability to move the electron beam at speeds of up to 8000 m/s allows for high-temperature heating of the surface layer up to 1000 • C during selective electron beam melting [2,[7][8][9]11,13], which reduces the number of microdefects and cracks. However, in selective laser melting technology, achieving a similar beam speed is impossible due to the limitations of the moving mirror system, which deflects the laser beam.…”

Section: Introductionmentioning

confidence: 99%

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Selective Laser Melting of Non-Weldable Nickel Superalloy: Microstructure, Cracks and Texture

Starikov,

Polozov,

Borisov

et al. 2023

Metals

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Additive manufacturing, particularly selective laser melting, presents exciting possibilities for fabricating components from high-temperature nickel-based superalloys. Controlling microstructural features and minimizing defects in fabricated specimens are critical challenges. This study explores the influence of process parameters on microstructure and defect formation in directionally solidified nickel-based superalloy specimens. We conducted a comprehensive analysis of selective laser melting process variables, including interdendritic spacing, crystallization times, and volumetric energy density. Electron backscatter diffraction analysis was employed to assess the feasibility of obtaining a directional structure in single-crystal nickel-based heat-resistant alloy specimens using selective laser melting. The study shows a significant correlation between reduced interdendritic spacing and increased defect formation. Longer crystallization times and higher volumetric energy density lead to decreased defect volumes and sizes. Electron backscatter diffraction analysis confirms the maintenance of preferential growth direction across subsequent layers. Our research underscores the importance of optimizing selective laser melting parameters, balancing refractory elements in alloy composition, and adopting strategies for enhancing crystallization times to minimize structural defects. This comprehensive approach ensures both heat resistance and minimal defects, facilitating the production of high-quality components. These findings contribute to advancing selective laser melting applications in critical industries like aerospace and power generation, where heat-resistant materials are paramount.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Selective Laser Melting of Non-Weldable Nickel Superalloy: Microstructure, Cracks and Texture

Starikov,

Polozov,

Borisov

et al. 2023

Metals

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Beyond Hot Cracking: Impact of Minor Elements on a Novel Ni-Based Superalloy for Additive Manufacturing

Dörries,

Haberland,

Burow

et al. 2024

The Minerals, Metals &Amp; Materials Series

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A new approach of preheating and powder sintering in electron beam powder bed fusion

Böhm,

Breuning,

Markl

et al. 2024

Int J Adv Manuf Technol

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Preheating is an essential process step in electron beam powder bed fusion. It has the purpose of establishing a sintered powder bed and maintaining an elevated temperature. The sintered powder bed reduces the risk of smoke and in combination with the elevated temperature improves the processability. Today, the line-ordering preheating scheme is widely used. This scheme does not take the previously built layers into account and results in an inhomogeneous elevated temperature and consequently in a variety of sinter degrees, which is disadvantageous for the process. The main challenge is now to modify this scheme to establish a homogeneous temperature distribution. This study addresses this challenge and analyses as well as optimises this scheme. A GPU-parallelised thermal model reveals a heterogeneous temperature distribution during preheating because of varying thermal conditions within a build job. In addition, a work-of-sintering model predicts that the sinter degree of the current powder layer on top of previously consolidated material is smaller than on top of the surrounding powder bed. This work aims to invert this trend to improve powder re-usage and material consolidation. Consequently, this work proposes an extension of the current scheme, compensating for the specific energy loss with local adjustments to the energy input. This adaption results in a uniform temperature distribution and advantageous sintering. Applying the proposed numerical model proves to be an effective method to analyse the evolving process conditions and tailor the local energy input, thereby improving the efficiency of the preheating step.

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Mechanical Performance of a Non-weldable Ni-Base Superalloy: Inconel 738 Fabricated by Electron Beam Melting

Cited by 11 publications

References 39 publications

Selective Laser Melting of Non-Weldable Nickel Superalloy: Microstructure, Cracks and Texture

Selective Laser Melting of Non-Weldable Nickel Superalloy: Microstructure, Cracks and Texture

Beyond Hot Cracking: Impact of Minor Elements on a Novel Ni-Based Superalloy for Additive Manufacturing

A new approach of preheating and powder sintering in electron beam powder bed fusion

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