A Review on Laser Powder Bed Fusion of Inconel 625 Nickel-Based Alloy

Tian, Zhihua; Zhang, Chaoqun; Wang, Dayong; Liu, Wen; Fang, Xiaojun; Wellmann, Daniel; Zhao, Yongtao; Tian, Yingtao

doi:10.3390/app10010081

Cited by 115 publications

(35 citation statements)

References 70 publications

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“…These were identified as Nb-rich MC carbides. Similar NbC precipitates have been reported in Alloy 625 produced by SLM and subjected to solution treatments [ 8 , 9 , 10 , 28 , 34 ]. The representative TEM micrograph of the solutionized alloy highlights the recrystallized structure with only a low amount of dislocations.…”

Section: Resultssupporting

confidence: 77%

Electron Backscattered Diffraction to Estimate Residual Stress Levels of a Superalloy Produced by Laser Powder Bed Fusion and Subsequent Heat Treatments

et al. 2020

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Metal Additive Manufacturing and Laser Powder Bed Fusion (LPBF), in particular, have come forth in recent years as an outstanding innovative manufacturing approach. The LPBF process is notably characterized by very high solidification and cooling rates, as well as repeated abrupt heating and cooling cycles, which generate the build-up of anisotropic microstructure and residual stresses. Post-processing stress-relieving heat treatments at elevated temperatures are often required in order to release some of these stresses. The effects of 1 h–hold heat treatments at different specific temperatures (solutionizing, annealing, stress-relieve and low-temperature stress-relieve) on residual stress levels together with microstructure characterization were therefore investigated for the popular Alloy 625 produced by LPBF. The build-up of residual stress is accommodated by the formation of dislocations that produce local crystallographic misorientation within grains. Electron backscattered diffraction (EBSD) was used to investigate local misorientation by means of orientation imaging, thereby assessing misorientation or strain levels, in turn representing residual stress levels within the material. The heavily constrained as-built material was found to experience full recrystallization of equiaxed grains after solutionizing at 1150 °C, accompanied by significant drop of residual stress levels due to this grains reconfiguration. Heat treatments at lower temperatures however, even as high as the annealing temperature of 980 °C, were found to be insufficient to promote recrystallization though effective to some extent to release residual stress through apparently dislocations recovery. Average misorientation data obtained by EBSD were found valuable to evaluate qualitatively residual stress levels. The effects of the different heat treatments are discussed and suggest that the peculiar microstructure of alloys produced by LPBF can possibly be transformed to suit specific applications.

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Section: Resultssupporting

confidence: 77%

Electron Backscattered Diffraction to Estimate Residual Stress Levels of a Superalloy Produced by Laser Powder Bed Fusion and Subsequent Heat Treatments

et al. 2020

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“…For example, IN718 and IN625 are well proved as the superalloys which are ready and prominent for the AM process. Wide research from different groups could achieve the crack-free LPBF IN718 [184,185] and IN625 [186,187] parts in a wide processing window. Among the easy-to-weld superalloys, although Hastelloy X can be successfully fabricated by LPBF in a defect-free condition, process parameter optimization is required [188].…”

Section: Additive Manufacturability Diagrammentioning

confidence: 99%

Alloy Design and Characterization of γ′ Strengthened Nickel-based Superalloys for Additive Manufacturing

2021

Linköping Studies in Science and Technology. Licentiate Thesis

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Nickel-based superalloys, an alloy system bases on nickel as the matrix element with the addition of up to 10 more alloying elements including chromium, aluminum, cobalt, tungsten, molybdenum, titanium, and so on. Through the development and improvement of nickel-based superalloys in the past century, they are well proved to show excellent performance at the elevated service temperature. Owing to the combination of extraordinary high-temperature mechanical properties, such as monotonic and cyclic deformation resistance, fatigue crack propagation resistance; and high-temperature chemical properties, such as corrosion and oxidation resistance, phase stability, nickel-based superalloys are widely used in the critical hot-section components in aerospace and energy generation industries. The success of nickel-based superalloy systems attributes to both the well-tailored microstructures with the assistance of carefully doped alloying elements, and the intently developed manufacturing processes. The microstructure of the modern nickel-based superalloys consists of a two-phase configuration: the intermetallic precipitates (Ni,Co)3(Al,Ti,Ta) known as γ′ phase dispersed into the austenite γ matrix, which is firstly introduced in the 1940s. The recently developed additive manufacturing (AM) techniques, acting as the disruptive manufacturing process, offers a new avenue for producing the nickel-based superalloy components with complicated geometries. However, γ′ strengthened nickel-based superalloys always suffer from the micro-cracking during the AM process, which is barely eliminated by the process optimization. On this basis, the new compositions of γ′ strengthened nickel-based superalloy adapted to the AM process are of great interest and significance. This study sought to design novel γ′ strengthened nickel-based superalloys readily for AM process with limited cracking susceptibility, based on the understanding of the cracking mechanisms. A two-parameter model is developed to predict the additive manufacturability for any given composition of a nickel-based superalloy. One materials index is derived from the comparison of the deformation-resistant capacity between dendritic and interdendritic regions, while another index is derived from the difference of heat resistant capacity of these two spaces. By plotting the additive manufacturability diagram, the superalloys family can be categorized into the easy-to-weld, fairly-weldable, and non-weldable regime with the good agreement of the existed knowledge. To design a novel superalloy, a Cr-Co-MoW -Al-Ti-Ta-Nb-Fe-Ni alloy family is proposed containing 921,600 composition recipes in total. Through the examination of additive manufacturability, undesired phase formation propensity, and the precipitation fraction, one composition of superalloy, MAD542, out of the 921,600 candidates is selected. Validation of additive manufacturability of MAD542 is carried out by laser powder bed fusion (LPBF). By optimizing the LPBF process parameters, the crack-free MAD542 part is achieved. I...

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“…AM processes used for metals mainly include powder bed fusion (PBF) [11][12][13][14][15], directed energy deposition (DED) and sheet lamination (SL) [10]. The commonly used metal AM processes include PBF-L (powder bed fusion utilizing a laser as the heat source) [16][17][18][19][20][21][22][23][24][25], DED-GMA (directed energy deposition with gas metal arc), and DED-L (directed energy deposition using laser beam as the heat source) [26,27]. According to the material feedstock, commonly used metal AM processes can be classified as powder-based and wire-based systems [28].…”

Section: Introductionmentioning

confidence: 99%

Wire Arc Additive Manufacturing of Stainless Steels: A Review

et al. 2020

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Wire arc additive manufacturing (WAAM) has been considered as a promising technology for the production of large metallic structures with high deposition rates and low cost. Stainless steels are widely applied due to good mechanical properties and excellent corrosion resistance. This paper reviews the current status of stainless steel WAAM, covering the microstructure, mechanical properties, and defects related to different stainless steels and process parameters. Residual stress and distortion of the WAAM manufactured components are discussed. Specific WAAM techniques, material compositions, process parameters, shielding gas composition, post heat treatments, microstructure, and defects can significantly influence the mechanical properties of WAAM stainless steels. To achieve high quality WAAM stainless steel parts, there is still a strong need to further study the underlying physical metallurgy mechanisms of the WAAM process and post heat treatments to optimize the WAAM and heat treatment parameters and thus control the microstructure. WAAM samples often show considerable anisotropy both in microstructure and mechanical properties. The new in-situ rolling + WAAM process is very effective in reducing the anisotropy, which also can reduce the residual stress and distortion. For future industrial applications, fatigue properties, and corrosion behaviors of WAAMed stainless steels need to be deeply studied in the future. Additionally, further efforts should be made to improve the WAAM process to achieve faster deposition rates and better-quality control.

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A Review on Laser Powder Bed Fusion of Inconel 625 Nickel-Based Alloy

Cited by 115 publications

References 70 publications

Electron Backscattered Diffraction to Estimate Residual Stress Levels of a Superalloy Produced by Laser Powder Bed Fusion and Subsequent Heat Treatments

Electron Backscattered Diffraction to Estimate Residual Stress Levels of a Superalloy Produced by Laser Powder Bed Fusion and Subsequent Heat Treatments

Alloy Design and Characterization of γ′ Strengthened Nickel-based Superalloys for Additive Manufacturing

Wire Arc Additive Manufacturing of Stainless Steels: A Review

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