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<p>In the present study, Inconel 625 superalloy powder with 0.5 wt% yttria-stabilized zirconia (YSZ) nanoparticles were used for selective laser melting (SLM) process. A high energy mixer with mixing duration up to 240&#xa0;min, were employed for mixing process. This study investigates the influence of selective laser melting (SLM) process parameters on the densification, defect formation, and microstructural evolution of an Inconel 625 composite reinforced with 0.5 wt% yttria-stabilized zirconia (YSZ) nanoparticles. Using a Taguchi L9 orthogonal array, we evaluated the effects of laser power (150–220&#xa0;J/s), scanning speed (500–700&#xa0;mm/s), and hatch spacing (0.02–0.08&#xa0;mm) on relative density and crack formation. The optimal combination for maximizing density was 150&#xa0;J/s laser power, 500&#xa0;mm/s scanning speed, and 0.02&#xa0;mm hatch spacing (Sample 1), which achieved a relative density of 96.4%. This value, however, is substantially lower than the ≥ 99% benchmark routinely reported for monolithic IN625 processed under optimized SLM conditions. Hatch spacing emerged as the dominant factor controlling crack formation, while laser power exhibited a nonlinear effect on porosity. Higher energy densities (&gt; 200&#xa0;J/s) promoted spherical gas pores due to gas entrapment, whereas lower energy densities led to lack-of-fusion defects. Quantitative EDS areal analysis confirmed a homogeneous YSZ distribution at the micrometer scale (0.47 ±‱0.08 wt%, matching the nominal 0.5 wt%). Nevertheless, the maximum relative density of 96.4% indicates that the addition of non-melting YSZ nanoparticles compromises full densification. Consequently, this work serves as a feasibility demonstration and parameter screening for YSZ-IN625 composites, while highlighting the need for further optimization—such as higher laser energy or substrate preheating—to approach the density levels of monolithic IN625.</p>

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Selective laser melting process parameters for IN625 superalloy composite reinforced with yttria-stabilized zirconia nanoparticles: correlation between processing parameters and defects

  • 期刊论文

  • 发表日期：

    2026年5月20日

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  • M. Mirzaei,
  • S. G. Shabestari,
  • B. Mohammad Sadeghi,
  • M. Amirjan,
  • M. Divandari

摘要

In the present study, Inconel 625 superalloy powder with 0.5 wt% yttria-stabilized zirconia (YSZ) nanoparticles were used for selective laser melting (SLM) process. A high energy mixer with mixing duration up to 240 min, were employed for mixing process. This study investigates the influence of selective laser melting (SLM) process parameters on the densification, defect formation, and microstructural evolution of an Inconel 625 composite reinforced with 0.5 wt% yttria-stabilized zirconia (YSZ) nanoparticles. Using a Taguchi L9 orthogonal array, we evaluated the effects of laser power (150–220 J/s), scanning speed (500–700 mm/s), and hatch spacing (0.02–0.08 mm) on relative density and crack formation. The optimal combination for maximizing density was 150 J/s laser power, 500 mm/s scanning speed, and 0.02 mm hatch spacing (Sample 1), which achieved a relative density of 96.4%. This value, however, is substantially lower than the ≥ 99% benchmark routinely reported for monolithic IN625 processed under optimized SLM conditions. Hatch spacing emerged as the dominant factor controlling crack formation, while laser power exhibited a nonlinear effect on porosity. Higher energy densities (> 200 J/s) promoted spherical gas pores due to gas entrapment, whereas lower energy densities led to lack-of-fusion defects. Quantitative EDS areal analysis confirmed a homogeneous YSZ distribution at the micrometer scale (0.47 ±‱0.08 wt%, matching the nominal 0.5 wt%). Nevertheless, the maximum relative density of 96.4% indicates that the addition of non-melting YSZ nanoparticles compromises full densification. Consequently, this work serves as a feasibility demonstration and parameter screening for YSZ-IN625 composites, while highlighting the need for further optimization—such as higher laser energy or substrate preheating—to approach the density levels of monolithic IN625.