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Effects of Microstructure Engineering on Laser Powder Bed Fusion Processed Superalloy IN718 through Inoculant Addition
Title
Effects of Microstructure Engineering on Laser Powder Bed Fusion Processed Superalloy IN718 through Inoculant Addition
Creator
Ho, I-Ting
Date
2023
Description
Additive manufacturing (AM) techniques can now be utilized as innovative tools that provide unlimited design flexibility for the fabrication...
Show moreAdditive manufacturing (AM) techniques can now be utilized as innovative tools that provide unlimited design flexibility for the fabrication of geometrically complex metallic structures. For production of Ni-base superalloy components used in advanced gas turbine engines, laser powder bed fusion (L-PBF), which is one of the AM techniques, is frequently used as it allows good metallurgical bonding of powder feedstock and simultaneously enables development of ultra-efficient power systems for aerospace propulsion, space exploration and power generation. One of the major challenges associated with additively manufactured Ni-base superalloy components is that the extreme temperature gradients encountered during processing negatively impact the underlying microstructure and mechanical properties of the material. Although the macroscopic shape and chemistry of the additively fabricated part may be identical to the conventionally manufactured part, the resulting properties are usually compromised. In an effort to make Ni-base superalloys more amenable for processing via additive manufacturing, varying levels of benign inoculants that promote may heterogeneously grain nucleation were blended into Inconel 718 (IN718) powder feedstock and used for processing via L-PBF to characterize the microstructural evolution. In the first study, 0.2 wt. % of micron-sized CoAl2O4 flakes was found to effectively change the grain morphology during the L-PBF process leading to significant reduction in crystallographic texture and thus resulting elastic anisotropy. Dispersion of nano-oxides resulting from the reduction of CoAl2O4 particles also contributed to improved tensile strength and steady creep strain rate. It should be noted, however, that, the multiple iterations of remelting as the result of deposition of new layers dissolved the Co-rich particles reduced from CoAl2O4 inoculants. Instead of having nucleation events contributed by elemental Co, the oxide agglomerates as a result of Marangoni convection seemed to be the major contribution to facilitating grain refinement by inhibiting the heat transfer in the surroundings. On the other hand, addition CoAl2O4 particles appeared to generally reduce the melt pool width while increase the melt pool depth by inhibiting the degree of heat transfer and Marangoni flow. The changes in melt pool dimension aided in improving the relative density and surface roughness of the bulk samples by generating better metallurgical bonding to the subsequent layers. As the trade-off, however, the changes in melt pool physics also enhanced the tendency for epitaxial growth and hence retarded the columnar-to-equiaxed transition unless oxide agglomerates are present. In addition to CoAl2O4, candidates including Co, TaCr2, TiB2, and CeO2 particles were also considered to be blended with the powder feedstock of IN718. After the L-PBF process, different degree of microstructural evolution was characterized with the addition of Co, TaCr2, TiB2, or CeO2 particles. It was found that the physical presence of inoculants may change the melt pool geometries that accounted for a comparatively more columnar-grained structure with <101> texture in samples containing Co and TaCr2 particles while a relatively equiaxed-grained structure with <001> texture in samples containing TiB2. The comparison between samples containing TiB2 and CeO2 further indicates that the phase transformation induced agglomeration will also reduce the effectiveness of inoculants due to decreasing nuclei density. Findings from this investigation demonstrate the resulting grain structure upon L-PBF can be profoundly impacted by both chemistry and physical properties of the inoculants. These effects may potentially be harnessed to effectively engineer the microstructure and optimize the properties of L-PBF processed Ni-base superalloys.
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Towards Understanding the Microstructure and Mechanical Properties of Additively Manufactured Ni-base Superalloys
Title
Towards Understanding the Microstructure and Mechanical Properties of Additively Manufactured Ni-base Superalloys
Creator
Tiparti, Dhruv Reddy
Date
2022
Description
Nickel-base superalloy components such as turbine discs typically undergo numerous manufacturing steps that contribute to increasing the cost...
Show moreNickel-base superalloy components such as turbine discs typically undergo numerous manufacturing steps that contribute to increasing the cost and the waste of excess materials. With advent of fusion based additive of manufacturing (AM) techniques, such components with complex geometry can be fabricated with great efficiency. However due to characteristically high energy densities, fast cooling rate, and layer-by-layer building process associated with AM; Ni-base superalloys with higher temperature performance are difficult to be fabricated by AM due to susceptibility to composition related defect formation, which is further exacerbated by anisotropic grain structures induced by the large thermal gradients present. Crack-free material can be fabricated but, in most cases, issues such as an anisotropic microstructure will prevail, and the balance of mechanical properties achieved may not be suitable for the desired applications. Several strategies exist to mitigate the challenges posed by additive manufacturing via post-processing such as hot-isostatic processing, annealing heat treatments, application of grain refining inoculants, etc. All these strategies utilized to mitigate issues with AM of Ni-base superalloys still require further study to understand their effects on the microstructure and mechanical properties. This work aims to evaluate the use of inoculant particles, and novel heat treatments on the microstructure and mechanical properties of different superalloys. First, the effect of varying amounts of CoAl2O4 inoculant ranging from 0 to 2 wt.% on the microstructure evolution of Inconel 718(IN718) fabricated by selective laser melting (SLM) was evaluated. The findings from this study indicated that additions of CoAl2O4 only resulted in a minor degree of grain refinement with slight increase in anisotropy; in addition, a CoAl2O4 ¬content above 0.2 wt.% resulted in the formation of agglomerate inclusions; and that to effectively utilize CoAl2O4 as a grain refining inoculant, process parameters must be further optimized while considering the formation of agglomerates, and other defects. Second, the application of CoAl2¬O4 was extended towards the Direct Energy Deposition (DED) of IN718. Here findings indicated that due to the modification of the thermophysical properties of the melt pool by oxide addition, an earlier onset of large columnar extending across multiple layers occurred while counteracting conditions required for equiaxed grain formation; and these CoAl2O4 were also found to exhibit a potent Zenner pinning effect that maintained the as-built grain structure despite application of extreme high treatment condition of 1200oC for 4 hrs. Third, the tensile and fatigue properties of the DED IN718 with CoAl2O4 were evaluated. Here, it was found that the addition of CoAl2O4 leads to a minor increase in tensile strength in the as-built condition attributed primarily to the fine oxide dispersion; a more modest increase in tensile strength in the heat-treated condition due to grain refinement induced by retaining the as-built grain structure; and that despite the increase in tensile strength with CoAl2O4 a corresponding increase in fatigue life did not occur. Lastly, the processing of René 65 conducted by laser-powder bed fusion(L-PBF) was done and compared to the conventionally cast and wrought material. Here, the effect of the difference in processing route in conjunction with heat treatments was evaluated to understand the creep and stress relaxation behavior. It was found that L-PBF of René 65 led to an overall improved resistance to deformation by creep and relaxation mechanism.
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Effect of Phosphorus Additions on Polycrystalline Ni-base Superalloys
Title
Effect of Phosphorus Additions on Polycrystalline Ni-base Superalloys
Creator
Li, Linhan
Date
2020
Description
In recent years, advanced polycrystalline Ni-base superalloys have been developed with elevated levels of γ′ forming elements and high level...
Show moreIn recent years, advanced polycrystalline Ni-base superalloys have been developed with elevated levels of γ′ forming elements and high level of refractory elements as solid-solution strengtheners in an effort to extend the temperature capability. Moreover, the properties of the grain boundaries become more important and this necessitates the need to study of effects of minor additions of interstitial P for grain structure optimization. Due to the increased level of refractory elements employed, powder-processed Ni-base superalloys tend to have a high propensity to form Topologically Close-Packed (TCP) phases, which was found to be further promoted by the addition of P. A systematic study of the phase stability of high refractory content powder-processed Ni-base superalloys with three levels of P additions revealed an increased tendency to form Laves phase as a function of P additions. Additions of P were discovered to not only depress the incipient melting temperature to stabilize the eutectic Laves phase, but also promote Laves phase formation during the aging heat treatment and the following isothermal exposure. During the thermal exposure, excessive formation of Laves phase promoted the formation of a basket-weave structure comprised of an intertwined mixture of Laves and Sigma phase. The stabilization of the Laves phase structure due to P additions was found to be consistent with Density Functional Theory (DFT) calculations and could be rationalized through structure maps that relate the valence electron concentration and relative size differences. Additionally, a variation of grain structure obtained via either a sub-solvus or super-solvus solution heat treatment was noted to some extent vary the P segregation level at high-angle grain boundaries, thereby affecting the phase stability. For a sub-solvus solutioned grain structure that possessed a high length density of high-angle grain boundaries, the Laves phase formation was depressed for alloys with a low level of P addition. However, the phase stability variation associated with Laves phase formation was moderate when high concentrations of P were present. The effect of P addition on the γ′ microstructure variation is limited, which was confirmed by microstructure observations as well as through the short-term 0.6%-strain stress relaxation tests at high temperature. Heat treatment variations to modify the secondary and tertiary γ′ microstructures were discovered to exert a much more significant influence on the 0.6%-strain stress relaxation behavior. When a higher initial strain of 2% was applied, the stress relaxation behavior of the powder-processed Ni-base superalloys was found to be microstructure independent. The creep ductility of Waspaloy was determined to be notably reduced by the P additions due to the enhanced precipitation of M23C6 carbide at the grain boundaries. Excessive precipitation of M23C6 carbide increased the likelihood of brittle fracture when tested under low temperature/high stress creep conditions. However, the P addition as well as the excessive precipitation of M23C6 carbide did not impact the creep behavior as the dominant deformation was transgranular in nature when tested under high temperature/low stress conditions.
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