Process optimization and mechanical properties of oxide dispersion strengthened nickel-based superalloy by selective laser melting

Wang, Guowei; Huang, Lan; Liu, Zecheng; Qin, Zijun; He, Weijun; Liu, Feng; Chen, Chao; Nie, Yan

doi:10.1016/j.matdes.2019.108418

Cited by 40 publications

(11 citation statements)

References 26 publications

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“…In a three-factor CCD, the model is composed of 8 factorial points (blue circles), a center point (red circle), and 6 star points which are at a distance (α) from the center point and are set to a default value of 1.6818 to ensure design rotatability as shown in Figure 2 (top view). The range of the factorial points (1,−1) for all three factors is identified based on the previous SDSS 2507 studies [36][37][38]. Then, the center and star points are calculated and reported, as seen in Table 2.…”

Section: Response Surface Methodologymentioning

confidence: 99%

“…Statistical techniques, such as the RSM and analysis of variance (ANOVA), have been previously adopted and proven to be useful in the process parameter optimization of LPBF technology [38][39][40]. Wang et al [38] investigated the LPBF process parameter effect on the sample microstructure and mechanical properties of a nickel-based superalloy using the RSM approach. They succeeded in increasing the resulting sample tensile strength by applying the RSM approach to optimize the process parameters.…”

Section: Introductionmentioning

confidence: 99%

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Process Parameter Optimization of 2507 Super Duplex Stainless Steel Additively Manufactured by the Laser Powder Bed Fusion Technique

Mulhi

Dehgahi

Waghmare

et al. 2023

Metals

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Laser powder bed fusion is an attractive technology for producing high-strength stainless steel alloys. Among the stainless steels, 2507 super duplex stainless steel (2507 SDSS) is known for its excellent combination of corrosion resistance and high strength. Although there are some studies that aimed at optimizing the laser powder bed fusion (LPBF) printing parameters to print highly dense 2507 SDSS parts; However, a full optimization study is not reported yet. This study aims at optimizing the printing parameters for 2507 SDSS, namely: laser power, scan speed, and hatch distance. The response surface methodology was used in generating a detailed design of experiment to investigate the different pore formation types over a wide energy density range (22.22–428.87 J/mm3), examine the effects of each process parameter and their interactions on the resulting porosity, and identify an optimized parameter set for producing highly dense parts. Different process parameters showed different pore formation mechanisms, with lack-of-fusion, metallurgical or gas, and keyhole regimes being the most prevalent pore types identified. The lack-of-fusion pores are observed to decrease significantly with increasing the energy density at low values. However, a gradual increase in the keyhole pores was observed at higher energy densities. An optimal energy density process window from 68.24 to 126.67 J/mm3 is identified for manufacturing highly dense (≥99.6%) 2507 SDSS parts. Furthermore, an optimized printing parameter set at a laser power of 217.4 W, a scan speed of 1735.7 mm/s, and a hatch distance of 51.3 µm was identified, which was able to produce samples with 99.961% relative density. Using the optimized parameter set, the as-built 2507 SDSS sample had a ferrite phase fraction of 89.3% with a yield and ultimate tensile strength of 1115.4 ± 120.7 MPa and 1256.7 ± 181.9 MPa, respectively.

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Section: Response Surface Methodologymentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Process Parameter Optimization of 2507 Super Duplex Stainless Steel Additively Manufactured by the Laser Powder Bed Fusion Technique

Mulhi

Dehgahi

Waghmare

et al. 2023

Metals

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“…In recent years, research and development into the selective laser melting (SLM) process has been actively pursued to improve the degree of freedom of part design, reduce the number of parts, and lower the cost via integrated fabrication. Several studies have been carried out on the application of the SLM process to materials such as titanium alloys [1,2], Ni-based superalloys [3][4][5][6], aluminum alloys [7,8], and steel materials [9,10]. These studies have revealed that it is important to set the process parameters (layer thickness, hatch spacing, laser power, and scan speed) within an appropriate range to fabricate parts with largely no defects or cracks.…”

Section: Introductionmentioning

confidence: 99%

Process Parameter Optimization Framework for the Selective Laser Melting of Hastelloy X Alloy Considering Defects and Solidification Crack Occurrence

et al. 2021

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Recent years have witnessed increasing demand for selective laser melting (SLM) in practical applications; however, determining the appropriate process parameter range remains challenging. In this study, a framework was developed to determine the appropriate process parameter range considering the occurrence of defects and cracks by conducting a single-track test and thermal elastoplastic analysis. Keyholing, balling, and the residual unmelted regions were considered defects. The occurrence of solidification cracking, which is predominant in the SLM of solution-strengthened Ni-based alloys, was considered. Using the proposed framework, we could fabricate a part with largely no defects or cracks, except for the edges, under the determined optimal process parameters.

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“…In the field of additive manufacturing, several researchers have used RSM for process parameter optimization. Wang et al [24] investigated the influences of some LPBF process parameters on the microstructure and mechanical properties of manufactured samples by RSM. They concluded that it was possible to increase the mechanical properties by the optimization of process parameters through applying RSM.…”

Section: Introductionmentioning

confidence: 99%

Optimizing Laser Powder Bed Fusion Parameters for IN-738LC by Response Surface Method

et al. 2020

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A method to find the optimum process parameters for manufacturing nickel-based superalloy Inconel 738LC by laser powder bed fusion (LPBF) technology is presented. This material is known to form cracks during its processing by LPBF technology; thus, process parameters have to be optimized to get a high quality product. In this work, the objective of the optimization was to obtain samples with fewer pores and cracks. A design of experiments (DoE) technique was implemented to define the reduced set of samples. Each sample was manufactured by LPBF with a specific combination of laser power, laser scan speed, hatch distance and scan strategy parameters. Using the porosity and crack density results obtained from the DoE samples, quadratic models were fitted, which allowed identifying the optimal working point by applying the response surface method (RSM). Finally, five samples with the predicted optimal processing parameters were fabricated. The examination of these samples showed that it was possible to manufacture IN738LC samples free of cracks and with a porosity percentage below 0.1%. Therefore, it was demonstrated that RSM is suitable for obtaining optimum process parameters for IN738LC alloy manufacturing by LPBF technology.

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Process optimization and mechanical properties of oxide dispersion strengthened nickel-based superalloy by selective laser melting

Cited by 40 publications

References 26 publications

Process Parameter Optimization of 2507 Super Duplex Stainless Steel Additively Manufactured by the Laser Powder Bed Fusion Technique

Process Parameter Optimization of 2507 Super Duplex Stainless Steel Additively Manufactured by the Laser Powder Bed Fusion Technique

Process Parameter Optimization Framework for the Selective Laser Melting of Hastelloy X Alloy Considering Defects and Solidification Crack Occurrence

Optimizing Laser Powder Bed Fusion Parameters for IN-738LC by Response Surface Method

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