Understanding mechanisms of microstructure evolution and defect formation is vital for advancing the fabrication of superalloy components and fostering confidence in additive manufacturing (AM) technologies. This keynote explores our current understanding of crack formation mechanisms in precipitation-strengthened nickel-base superalloys fabricated using powder bed fusion (PBF) additive manufacturing, a persistent challenge also seen in fusion welding. While the rich knowledge from welding of these alloys can be immensely helpful in understanding the observed cracking phenomena, the thermo-mechanical and thermo-metallurgical boundary conditions during the PBF process are distinctly different and immensely complex. Following background information on laser and electron beam powder bed fusion additive manufacturing, this paper reviews potential cracking mechanisms in γ′-strengthened nickel-base superalloys based on the welding literature and the increasing number of AM publications. Finally, a case study is presented to highlight characterization and modeling techniques that can be employed to understand crack formation mechanisms in PBF. Identification of cracking mechanisms remains a challenging task but is critical for guiding material and process development in additive manufacturing.

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On the Cracking Mechanisms in Powder Bed Fusion Additive Manufacturing of Nickel-Base Superalloys

  • Carolin Fink,
  • Alivia Mourot,
  • Brian Welk,
  • Sriram Vijayan,
  • Adam Hope,
  • Andrew Breen,
  • Simon Ringer,
  • Joerg Jinschek

摘要

Understanding mechanisms of microstructure evolution and defect formation is vital for advancing the fabrication of superalloy components and fostering confidence in additive manufacturing (AM) technologies. This keynote explores our current understanding of crack formation mechanisms in precipitation-strengthened nickel-base superalloys fabricated using powder bed fusion (PBF) additive manufacturing, a persistent challenge also seen in fusion welding. While the rich knowledge from welding of these alloys can be immensely helpful in understanding the observed cracking phenomena, the thermo-mechanical and thermo-metallurgical boundary conditions during the PBF process are distinctly different and immensely complex. Following background information on laser and electron beam powder bed fusion additive manufacturing, this paper reviews potential cracking mechanisms in γ′-strengthened nickel-base superalloys based on the welding literature and the increasing number of AM publications. Finally, a case study is presented to highlight characterization and modeling techniques that can be employed to understand crack formation mechanisms in PBF. Identification of cracking mechanisms remains a challenging task but is critical for guiding material and process development in additive manufacturing.