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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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Laser Powder Bed Fusion Of Cost-Effective Non-Spherical Ti-6Al-4V Powder
Title
Laser Powder Bed Fusion Of Cost-Effective Non-Spherical Ti-6Al-4V Powder
Creator
Asherloo, Mohammadreza
Date
2023
Description
This comprehensive research delves into the intricate dynamics of Laser Powder Bed Fusion (L-PBF) of Ti-6Al-4V powders, emphasizing the...
Show moreThis comprehensive research delves into the intricate dynamics of Laser Powder Bed Fusion (L-PBF) of Ti-6Al-4V powders, emphasizing the potential of non-spherical, hydride-dehydride (HDH) powders as a cost-efficient alternative to traditional spherical powders. The study systematically explores the interplay between powder morphology, granulometry, and various post-processing treatments in shaping the resultant microstructure, porosity, and mechanical properties of L-PBF fabricated Ti-6Al-4V components.Initial investigations focused on the flowability, packing density, and resultant density of L-PBF parts using HDH powders with varying size distributions. Through meticulous optimization of laser parameters, parts with a relative density exceeding 99.5% were achieved, even at production rates 1.5–2 times higher than conventional LPBF processes. Dynamic synchrotron X-ray imaging provided insights into laser-powder interactions, revealing key mechanisms of porosity formation associated with HDH powders. Further microstructural examinations highlighted the formation of columnar β grains with acicular α/α′ phases in the as-built condition. Mechanical tests, including fatigue assessments under fully-reversed tension-compression conditions, revealed the critical role of surface roughness in fatigue performance. Notably, mechanical grinding significantly improved fatigue strength, especially in the high cycle fatigue region, by eliminating surface micro-notches. X-ray diffraction analyses further elucidated the stress and micro-strain profiles, offering insights into the material's deformation mechanisms. A pivotal discovery was the presence of α/α′ on prior β/β grain boundaries, challenging the prevailing notion that high cooling rates in L-PBF preclude β/β grain boundary variant selection. Electron backscatter diffraction and synchrotron X-ray imaging illuminated the role of powder characteristics in locally modulating cooling rates, leading to β/β grain boundary α′ lath growth. Lastly, the research underscored the multifaceted interdependencies among contouring, powder granulometry, Hot Isostatic Pressing (HIP), and mechanical surface treatments. A pronounced increase in sub-surface porosities was identified when contouring was combined with fine powder granulometry. However, post-HIP treatments induced a phase transformation from martensitic α′ to a basket-weave α+β microstructure, enhancing the material's fatigue resistance to levels comparable to wrought Ti-6Al-4V. In summation, this doctoral research offers a holistic understanding of the L-PBF process for Ti-6Al-4V, emphasizing the viability of non-spherical HDH powders and providing a roadmap for parameter optimization, defect minimization, and mechanical property enhancement in L-PBF-fabricated Ti-6Al-4V structures.
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