Process parameter optimization for selective laser melting of Inconel 718 superalloy and the effects of subsequent heat treatment on the microstructural evolution and mechanical properties

Wang, Wenquan; Wang, Suyu; Zhang, Xinge; Chen, Fei; Xu, Yuxin; Tian, Yingtao

doi:10.1016/j.jmapro.2021.02.004

Cited by 33 publications

(7 citation statements)

References 38 publications

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“…Ravichander et al [33] identified the effect of scan strategy on residual stress and studied the metallurgical interactions between the mechanical and microstructural properties within the IN718 superalloy. Wang et al [34] optimized the process parameters for selective laser melting of Inconel 718 and further established the relationship equation between the relative density of SLMed samples and the energy density coupled by laser parameters. Zhu et al [35] reported that fine and coarse columnar dendritic microstructure of as-deposited IN718 superalloy were, respectively, obtained at different laser power and laser beam diameter and found that the Nb-and Mo-rich Laves phase is formed in the interdendritic regions, which weakens the mechanical property of the as-deposited IN718 superalloy [8,[36][37][38].…”

Section: Introductionmentioning

confidence: 99%

Effect of Laser Energy Density on the Microstructure and Microhardness of Inconel 718 Alloy Fabricated by Selective Laser Melting

Niu

et al. 2022

Crystals

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This work focused on the effects of laser energy density on the relative density, microstructure, and microhardness of Inconel 718 alloy manufactured by selective laser melting (SLM). The microstructural architectures, element segregation behavior in the interdendritic region and the evolution of laves phases of the as-SLMed IN718 samples were analyzed by optical metallography (OM), scanning electron microscopy (SEM), energy dispersive spectrometer (EDS), and electron probe microanalysis (EPMA). The results show that with an increase in the laser volume energy density, the relative density and the microhardness firstly increased and then decreased slightly. It also facilitates the precipitation of Laves phase. The variation of mechanical properties of the alloy can be related to the densification degree, microstructure uniformity, and precipitation phase content of Inconel 718 alloy.

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Section: Introductionmentioning

confidence: 99%

Effect of Laser Energy Density on the Microstructure and Microhardness of Inconel 718 Alloy Fabricated by Selective Laser Melting

Niu

et al. 2022

Crystals

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“…LPBF uses a high-intensity laser to melt metal powder using a predefined scanning path for each layer, so layers are stacked to form a three-dimensional (3D) object. The printing parameters include laser power, scanning speed, hatch space, and layer thickness, and these are defined before the printing process is conducted [ 5 , 6 , 7 ]. These four parameters affect the relative density, surface roughness, and mechanical properties of an as-built object that is produced using an LPBF printer.…”

Section: Introductionmentioning

confidence: 99%

Laser Powder Bed Fusion of Inconel 718 Tools for Cold Deep Drawing Applications: Optimization of Printing and Post-Processing Parameters

et al. 2023

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Inconel 718 (IN 718) powder is used for a laser powder bed fusion (LPBF) printer, but the mechanical properties of the as-built object are not suited to cold deep drawing applications. This study uses the Taguchi method to design experimental groups to determine the effect of various factors on the mechanical properties of as-built objects produced using an LPBF printer. The optimal printing parameters are defined using the result for the factor response to produce an as-built object with the greatest ultimate tensile strength (UTS), and this is used to produce a specimen for post-processing, including heat treatment (HT) and surface finishing. The HT parameter value that gives the maximum UTS is the optimal HT parameter. The optimal printing and HT parameter values are used to manufacture a die and a punch to verify the suitability of the manufactured tool for deep drawing applications. The experimental results show that the greatest UTS is 1091.33 MPa. The optimal printing parameters include a laser power of 190 W, a scanning speed of 600 mm/s, a hatch space of 0.105 mm and a layer thickness of 40 μm, which give a UTS of 1122.88 MPa. The UTS for the post-processed specimen increases to 1511.9 MPa. The optimal parameter values for HT are heating to 720 °C and maintaining this temperature for 8 h, decreasing the temperature to 620 °C and maintaining this temperature for 8 h, and cooling to room temperature in the furnace. Surface finishing increases the hardness to HRC 55. Tools, including a punch and a die, are manufactured using these optimized parameter values. The deep drawing experiment demonstrates that the manufactured tools that are produced using these values form a round cup of Aluminum alloy 6061. The parameter values that are defined can be used to manufacture IN 718 tools with a UTS of more than 1500 MPa and a hardness of more than 50 HRC, so these tools are suited to cold deep drawing specifications.

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“…There are many studies about parameter optimization for Ni superalloys processed via L-PBF in the literature. Most of the studied materials are easy-to-weld grades, such as In718 [16,17], In625 [18] and Hastelloy X [19], for which the effect of alloying elements on cracking behavior was also studied [20]. Furthermore, hard-to-weld compositions have been investigated, such as CM247 LC [21,22], CMSX486 [23], In738 [24] and In939 [25].…”

Section: Introductionmentioning

confidence: 99%

Parameters Optimization and Repeatability Study on Low-Weldable Nickel-Based Superalloy René 80 Processed via Laser Powder–Bed Fusion (L-PBF)

Martelli

Sivo

Calignano

et al. 2023

Metals

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This work aims to investigate the processability of René 80 via laser powder–bed fusion (L-PBF). René 80 is a poorly weldable Ni-superalloy, currently processed via investment casting to fabricate turbine blades working at an operating temperature of about 850 °C. The L-PBF parameters optimization aims to increase part integrity and enhance processing repeatability. This part was tackled by creating a complete design of experiments (DOE) in which laser power, scan speed and hatching distance were varied accordingly. Optimizing the abovementioned parameters minimized the crack density and pore area fraction. Hence, five parameter sets leading to a crack density lower than 100 µm/mm2 and a pore fraction between 0.045% and 0.085% were selected. Furthermore, the intra-print repeatability was studied by producing three specimens’ repetitions for each optimal set of parameters in the same build. The porosity value obtained was constant among repetitions, and the crack density (around 75 µm/mm2) had a slight standard deviation. The third step of the research assessed the inter-prints repeatability by producing a replica of the five selected parameter sets in a different build and by comparing the results with those studied previously. According to this latter study, the porosity fraction (ca. 0.06%) was constant in intra- and inter-print conditions. Conversely, crack density was lower than 100 µm/mm2 only in three sets of parameters, regardless of the intra- or inter-build cross-check. Finally, the best parameter set was chosen, emphasizing the average flaw fraction (least possible value) and repeatability. Once the optimal densification of the samples was achieved, the alloy’s microstructural features were also investigated.

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Process parameter optimization for selective laser melting of Inconel 718 superalloy and the effects of subsequent heat treatment on the microstructural evolution and mechanical properties

Cited by 33 publications

References 38 publications

Effect of Laser Energy Density on the Microstructure and Microhardness of Inconel 718 Alloy Fabricated by Selective Laser Melting

Effect of Laser Energy Density on the Microstructure and Microhardness of Inconel 718 Alloy Fabricated by Selective Laser Melting

Laser Powder Bed Fusion of Inconel 718 Tools for Cold Deep Drawing Applications: Optimization of Printing and Post-Processing Parameters

Parameters Optimization and Repeatability Study on Low-Weldable Nickel-Based Superalloy René 80 Processed via Laser Powder–Bed Fusion (L-PBF)

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