Additive manufacturing of nickel-based superalloys: A state-of-the-art review on process-structure-defect-property relationship

Mostafaei, Amir; Ghiaasiaan, Reza; Ho, I‐Ting; Strayer, Seth; Chang, Kai-Chun; Shamsaei, Nima; Shao, Shuai; Paul, Santanu; Yeh, An‐Chou; Tin, Sammy; To, Albert C.

doi:10.1016/j.pmatsci.2023.101108

Cited by 94 publications

(19 citation statements)

References 423 publications

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“…Metal AM has been extensively reviewed by various research groups from different perspectives, for instance the microstructure [19,20], processing [21,22], numerical modeling [23][24][25], mechanical properties [21,26,27], and post-treatments [28][29][30]. The alloy development has also been reviewed, including Ti-based [31][32][33][34][35], Al-based [20,36], Nibased [37,38], Fe-based [2,39], and Mg-based alloys [40,41]. However, most of the work focuses on adapting existing alloys to the L-PBF process, rather than developing specific alloys dedicated to L-PBF.…”

Section: Introductionmentioning

confidence: 99%

Alloy design for laser powder bed fusion additive manufacturing: a critical review

Liu,

Zhou,

Liang

et al. 2024

Int. J. Extrem. Manuf.

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Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM persisted. This is due to the fact that commercial alloys are primarily designed for conventional casting or forging processes, without considering the fast cooling rates, steep temperature gradients, and multiple thermal cycles of L-PBF. To address this, there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies. This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF. It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting the existing alloys for L-PBF. The review begins by discussing the features of L-PBF processes, focusing on rapid solidification and intrinsic heat treatment. Next, the printability of the four main existing alloys (Fe-, Ni-, Al-, and Ti-based alloys) is critically assessed, with a comparison to their conventional weldability. It was found that the weldability criteria are not always applicable in estimating printability. Furthermore, the review presents recent advances in alloy development and associated strategies, categorizing them into crack mitigation-oriented, microstructure manipulation-oriented, and machine learning-assisted approaches. Lastly, an outlook and suggestions are given to highlight the issues that need be addressed in future work.

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Section: Introductionmentioning

confidence: 99%

Alloy design for laser powder bed fusion additive manufacturing: a critical review

Liu,

Zhou,

Liang

et al. 2024

Int. J. Extrem. Manuf.

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“…Among the various AM technologies, laser powder bed fusion (L-PBF) draws significant interest due to a lower surface roughness and complex geometry for the printed parts [6], making it account for about 85% of the metal AM market share [7]. Till now, L-PBF has been broadly implemented to fabricate a variety of materials, such as titanium alloy [8][9][10][11], nickel-based superalloy [12], aluminum alloy [13,14], magnesium alloy [15], metallic glass [16], and shape memory alloy [17]. However, there are still several challenges preventing the broad industrial applications of L-PBF.…”

Section: Introductionmentioning

confidence: 99%

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Sun,

Chen,

Liu

et al. 2023

Int. J. Extrem. Manuf.

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Laser powder bed fusion (L-PBF) has attracted significant attention since its inception, providing unprecedented advantages to fabricate metallic components with complex geometry. The quality and performance of as-printed alloys is an intricate function consisting of numerous factors linking the feedstock powders, manufacturing, and post-treatment. As the starting materials, powders play a critical role in influencing the printing consistency, total fabrication cost, and mechanical properties. In consideration of its importance for L-PBF, the present review aims to review the recent progress on metallic powders for L-PBF focusing on powder characterization, powder fabrication, and powder reuse. The methods of powder characterization and fabrication were presented in the beginning by analyzing the principles and corresponding advantages and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed focusing on steels, nickel-based superalloys, Ti and Ti alloys, and Al alloys. The evolution trend of powders and as-printed parts varies for different alloy systems based on the existing studies, which makes the proposal of a unified reuse protocol infeasible. Finally, perspectives are presented to cater to the increasing applications of AM technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total cost from the perspective of powders.

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“…11 These revolutionary innovations offer key advantages such as cost-effectiveness, reduced energy consumption, the ability to fabricate complex geometries, the possibility of reusing waste material, and a decreased need for tooling. 12 AM has been successfully utilized to build 3D components using different metals, including steels and stainless steels, 13 Al alloys, 14 Mg alloys, 15 Ti alloys, 16 pure copper, 17 superalloys, 18 and Cu-based alloys. 19 Unlike many commercial alloys such as stainless steels 20 and titanium alloys, 21 the corrosion behavior of additively manufactured (AMed) copper and its alloys has not been thoroughly reviewed.…”

Section: Introductionmentioning

confidence: 99%

A review of the corrosion behavior of conventional and additively manufactured nickel–aluminum bronze (NAB) alloys: current status and future challenges

Morshed-Behbahani,

Bishop,

Nasiri

2023

Mater. Horiz.

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Additive manufacturing of nickel-based superalloys: A state-of-the-art review on process-structure-defect-property relationship

Cited by 94 publications

References 423 publications

Alloy design for laser powder bed fusion additive manufacturing: a critical review

Alloy design for laser powder bed fusion additive manufacturing: a critical review

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

A review of the corrosion behavior of conventional and additively manufactured nickel–aluminum bronze (NAB) alloys: current status and future challenges

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