Alloys-by-design: Application to new superalloys for additive manufacturing

Tang, Yuanbo T.; Panwisawas, Chinnapat; Ghoussoub, Joseph N.; Gong, Yilun; Clark, John W.; Németh, André A. N.; McCartney, D.G.; Reed, Roger C.

doi:10.1016/j.actamat.2020.09.023

Cited by 297 publications

(159 citation statements)

References 56 publications

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“…It should be also noted that recent proposed AM γ′ strengthened nickelbased superalloys which are designed for the AM process, e.g. ABD850AM, ABD900AM [192] by OxMet technologies and developed by using Alloys by Design® approach [135,193], and ExpAM [194] developed by Carpenter Technology Corporation, are located at this region. These AM superalloys are readily adopted for the LPBF process after processing parameter optimization.…”

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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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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“…In what follows, it is emphasized that only material in the as-printed condition is considered. [4]) with γ precipitates.…”

Section: Assessment Of Additive Manufacturabilitymentioning

confidence: 99%

“…Can existing metallic alloys be made to process well under the extreme cooling rates and stress-states induced [2,3]? Indeed, much current research emphasizing process optimization assumes that this will be the case.Or alternatively, will new grades of alloy be necessary with novel compositions and behavioral characteristics designed specifically for the process [4]?…”

Section: Introductionmentioning

confidence: 99%

On the Influence of Alloy Chemistry and Processing Conditions on Additive Manufacturability of Ni-Based Superalloys

Tang

Panwisawas

Németh

et al. 2020

The Minerals, Metals &Amp; Materials Series

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The susceptibility of nickel-based superalloys to processing-induced crack formation during laser powder-bed additive manufacturing is studied. Twelve different alloys -some of existing (heritage) type but also other newly-designed ones -are considered. A strong inter-dependence of alloy composition and processability is demonstrated. Stereological procedures are developed to enable the two dominant defect types found -solidification cracks and solid-state ductility dip cracks -to be distinguished and quantified. Differential scanning calorimetry, creep stress relaxation tests at 1000 • C and measurements of tensile ductility at 800 • C are used to interpret the effects of alloy composition. A model for solid-state cracking is proposed, based on an incapacity to relax the thermal stress arising from constrained differential thermal contraction; its development is supported by experimental measurements using a constrained bar cooling test. A modified solidification cracking criterion is proposed based upon solidification range but including also a contribution from the stress relaxation effect. This work provides fundamental insights into the role of composition on the additive manufacturability of these materials.

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“…For instance, it is well established that the permanent cyclic deformations occur due to slip irreversibility, which itself stems from slip or twinning of crystal lattice 32 . Therefore, grain‐scale plastic strain and the associated energy may be considered as key factors for the accurate modeling of fatigue damage, particularly in the case of additively manufactured materials where the presence of internal defects caused during the layer‐by‐layer building of a component significantly affects the microstructure behavior 33–36 …”

Section: Introductionmentioning

confidence: 99%

General quantification of fatigue damage with provision for microstructure: A review

Jirandehi

Khonsari

2021

Fatigue Fract Eng Mat Struct

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Recent developments in microstructure‐sensitive computational modeling and experimental verification have provided significant insight on how one can estimate fatigue damage and predict useful life. As a myriad of methods and approaches are available, it is important to understand how to properly utilize them in a unified and efficient framework for the quantification of damage in safety‐critical components such as jet engine fan blades, gas turbine disks, and airframe structural connections. To this end, the microstructure‐sensitive studies considering crystal plasticity are reviewed, and methods for implementing the statistical representations of material microstructure are presented. Finally, a computational crystal plasticity approach utilizing the statistical representation of parameters and a new thermodynamically based framework is suggested.

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Alloys-by-design: Application to new superalloys for additive manufacturing

Cited by 297 publications

References 56 publications

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

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

On the Influence of Alloy Chemistry and Processing Conditions on Additive Manufacturability of Ni-Based Superalloys

General quantification of fatigue damage with provision for microstructure: A review

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