Cracking Behavior of René 104 Nickel-Based Superalloy Prepared by Selective Laser Melting Using Different Scanning Strategies

Peng, Kai; Duan, Ranxi; Liu, Zuming; Lv, Xueqian; Li, Quan; Zhao, Fan; Bing, Wei; Nong, Bizhong; Wei, Shizhong

doi:10.3390/ma13092149

Cited by 16 publications

(3 citation statements)

References 42 publications

(50 reference statements)

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“…Generally, the AM-process-induced cracking is heavily dominated by the poor cracking resistance in the ID region rather than DC. From extensive research [165][166][167][168][169], the majority of the cracks are observed in the ID spaces. In addition, a high portion of the cracks is specifically identified at the grain boundaries.…”

Section: Segregation Behavior In Lpbfmentioning

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: Segregation Behavior In Lpbfmentioning

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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“…Hence, a galvanic cell was developed with the NiCoCr-based superalloy matrix acting as the anode and the uniformly distributed Y 2 O 3 nanoparticles playing the role of the cathode. As a result, the corrosion mechanism was transformed from a local and pitting erosion to a homogeneous erosion [ 26 , 27 , 28 , 29 ]. Additionally, as an additional advantage Y 2 O 3 nanoparticles, it has been also reported that they can prevent the expansion of pits within the corrosion medium by serving as an inert barrier [ 30 ].…”

Section: Resultsmentioning

confidence: 99%

Crack Inhibition and Performance Modification of NiCoCr-Based Superalloy with Y2O3 Nanoparticles by Laser Metal Deposition

et al. 2023

Materials

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A new precipitation strengthening NiCoCr-based superalloy with favorable mechanical performance and corrosion resistance was designed for ultra-supercritical power generation equipment. The degradation of mechanical properties and steam corrosion at high temperatures put forward higher requirements for alternative alloy materials; however, when the superalloy is processed to form complex shaped components through advanced additive manufacturing techniques such as laser metal deposition (LMD), hot cracks are prone to appear. This study proposed that microcracks in LMD alloys could be alleviated with powder decorated by Y2O3 nanoparticles. The results show that adding 0.5 wt.% Y2O3 can refine grains significantly. The increase in grain boundaries makes the residual thermal stress more uniform to reduces the risk of hot cracking. In addition, the addition of Y2O3 nanoparticles enhanced the ultimate tensile strength of the superalloy at room temperature by 18.3% compared to original superalloy. The corrosion resistance was also improved with 0.5 wt.% Y2O3, which was attributed to the reduction of defects and the addition of inert nanoparticles.

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“…Song et al [14] used 3D simulation to study the distribution of residual stress in Ti 6 Al 4 V manufactured by L-PBF, nding that the scanning strategy had a great in uence on the temperature eld. Peng et al [15] studied three scanning strategies of the snake, stripe partition, and chessboard partition, proposing that it is necessary to design scanning strategies with optimized scanning partitions and overlaps to avoid cracking and acquire a high-quality, near fully dense, lowweldable Nickel-based superalloy using SLM.…”

Section: Introductionmentioning

confidence: 99%

The optimization of residual stress in arc bridge Hastelloy X components fabricated by Laser Powder Bed Fusion

Liu,

Fang,

et al. 2023

Int J Adv Manuf Technol

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Laser Powder Bed Fusion (L-PBF) has been widely used in various elds, but due to the inherent complex thermal history and ultra-high solidi cation rate in the L-PBF process, detrimental residual stresses inevitably form inside the component. In this study, the formation mechanisms of residual stress and the strategies to reduce them were investigated during L-PBF of Hastelloy components. Components with simple block geometry were rst fabricated with different deposition strategies, i.e., scanning island size and rotation angle. The microstructure and residual stress of these samples were characterized. The optimal deposition strategy in terms of maximum tensile residual stress was then used to deposit the arc bridge components with complex geometry. The results clearly show that different deposition strategy is needed for components with complex geometry due to the change in cross-sectional area and the different heat transfer behavior between the new deposition layer and the previously deposited solid layer.Finally, the arch bridge samples with no warping deformation were achieved by optimized random scanning strategies and crossline scanning strategies. The results provided in this study thus provide a theoretical basis for tailoring residual stress during L-PBF of complex components.

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Cracking Behavior of René 104 Nickel-Based Superalloy Prepared by Selective Laser Melting Using Different Scanning Strategies

Cited by 16 publications

References 42 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

Crack Inhibition and Performance Modification of NiCoCr-Based Superalloy with Y2O3 Nanoparticles by Laser Metal Deposition

The optimization of residual stress in arc bridge Hastelloy X components fabricated by Laser Powder Bed Fusion

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