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<p>The creep and tensile behavior of Waspaloy, a <i>γ</i>′-strengthened nickel-based superalloy, processed by Wire Arc Additive Manufacturing using Cold Metal Transfer (WAAM–CMT) was investigated for repair applications. Mechanical properties of the bulk material were assessed up to 850&#xa0;°C in both the As-Built (AB) and Post-Weld Heat Treated (PWHT) conditions, with particular attention to the effect of the loading direction. The AB microstructure consisted of large columnar grains with ultra-fine <i>γ</i>′ precipitates and serrated boundaries pinned by carbides, providing considerable hardening despite being out-of-equilibrium. PWHT promoted <i>γ</i>′ coarsening and secondary carbide formation, enhancing yield and tensile strength to levels comparable with coarse-grained wrought Waspaloy. A shallow heat-affected zone (300 to 600&#xa0;<i>µ</i>m) was identified, and digital image correlation analysis of strain localization confirmed the good mechanical strength of the interface. Tensile testing revealed weak anisotropy (&lt; 9 pct) in strength, with AB samples exhibiting higher ductility. PWHT was particularly efficient at elevated temperatures, enabling properties equivalent to fine-grained wrought Waspaloy. Creep testing showed <i>in situ</i> aging and an initial contraction in the AB material. PWHT improved creep resistance at 700&#xa0;°C to 750&#xa0;°C but degraded performance at 800&#xa0;°C to 850&#xa0;°C, with strong anisotropy in creep life and strain at rupture. These findings establish WAAM–CMT as a promising repair technique for aircraft components.</p>

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Creep and Tensile Properties of Waspaloy Produced by Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年12月3日

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  • Marjolaine Sazerat,
  • Alice Cervellon,
  • Sophie Gillet,
  • Samuel Hemery,
  • Azdine Nait-Ali,
  • Patrick Villechaise,
  • Roland Fortunier,
  • Jonathan Cormier

摘要

The creep and tensile behavior of Waspaloy, a γ′-strengthened nickel-based superalloy, processed by Wire Arc Additive Manufacturing using Cold Metal Transfer (WAAM–CMT) was investigated for repair applications. Mechanical properties of the bulk material were assessed up to 850 °C in both the As-Built (AB) and Post-Weld Heat Treated (PWHT) conditions, with particular attention to the effect of the loading direction. The AB microstructure consisted of large columnar grains with ultra-fine γ′ precipitates and serrated boundaries pinned by carbides, providing considerable hardening despite being out-of-equilibrium. PWHT promoted γ′ coarsening and secondary carbide formation, enhancing yield and tensile strength to levels comparable with coarse-grained wrought Waspaloy. A shallow heat-affected zone (300 to 600 µm) was identified, and digital image correlation analysis of strain localization confirmed the good mechanical strength of the interface. Tensile testing revealed weak anisotropy (< 9 pct) in strength, with AB samples exhibiting higher ductility. PWHT was particularly efficient at elevated temperatures, enabling properties equivalent to fine-grained wrought Waspaloy. Creep testing showed in situ aging and an initial contraction in the AB material. PWHT improved creep resistance at 700 °C to 750 °C but degraded performance at 800 °C to 850 °C, with strong anisotropy in creep life and strain at rupture. These findings establish WAAM–CMT as a promising repair technique for aircraft components.