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arXiv · 2109.15274

On the influence of alloy composition on the additive manufacturability of Ni-based superalloys

Joseph N. Ghoussoub·Yuanbo T. Tang·William J B. Dick-Cleland·André A. N. Németh·Yilun Gong·D. Graham McCartney·Alan C. F. Cocks·Roger C. Reed
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Abstract

The susceptibility of nickel-based superalloys to processing-induced crack formation during laser powder-bed additive manufacturing is studied. Twelve different alloys -- some of existing (heritage) type but also other newly-designed ones -- are considered. A strong inter-dependence of alloy composition and processability is demonstrated. Stereological procedures are developed to enable the two dominant defect types found -- solidification cracks and solid-state ductility dip cracks -- to be distinguished and quantified. Differential scanning calorimetry, creep stress relaxation tests at 1000$^\circ$C and measurements of tensile ductility at 800$^\circ$C are used to interpret the effects of alloy composition. A model for solid-state cracking is proposed, based on an incapacity to relax the thermal stress arising from constrained differential thermal contraction; its development is supported by experimental measurements using a constrained bar cooling test. A modified solidification cracking criterion is proposed based upon solidification range but including also a contribution from the stress relaxation effect. This work provides fundamental insights into the role of composition on the additive manufacturability of these materials.

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Joseph N. Ghoussoub, Yuanbo T. Tang, William J B. Dick-Cleland, André A. N. Németh, Yilun Gong, D. Graham McCartney, Alan C. F. Cocks, Roger C. Reed. 2021-09-30. On the influence of alloy composition on the additive manufacturability of Ni-based superalloys. https://doi.org/10.1007/s11661-021-06568-z

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