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Additive manufacturing of Ni-based superalloys: The outstanding issues

Published online by Cambridge University Press:  10 October 2016

Moataz M. Attallah ,
Rachel Jennings ,
Xiqian Wang  and
Luke N. Carter
Moataz M. Attallah
Affiliation:
Advanced Materials and Processing Lab, School of Metallurgy and Materials, University of Birmingham, UK; [email protected]
Rachel Jennings
Affiliation:
Advanced Materials and Processing Lab, School of Metallurgy and Materials, University of Birmingham, UK; [email protected]
Xiqian Wang
Affiliation:
Advanced Materials and Processing Lab, School of Metallurgy and Materials, University of Birmingham, UK; [email protected]
Luke N. Carter
Affiliation:
Advanced Materials and Processing Lab, School of Metallurgy and Materials, University of Birmingham, UK; [email protected]
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Abstract

There is increasing interest in the use of additive manufacturing (AM) for Ni-based superalloys due to their various applications in the aerospace and power-generation sectors. Ni-based superalloys are known to have a complex chemistry, with over a dozen alloying elements in most alloys, enabling them to achieve outstanding high-temperature mechanical performance as well as oxidation resistance when processed using conventional routes (e.g., casting and forging). Nonetheless, this complex chemistry results in the formation of various phases that could affect their processability using AM, resulting in cracking. Furthermore, due to the directional solidification and rapid cooling associated with AM processes, the alloys experience significant anisotropy due to the epitaxially grown microstructure, as well as the residual stresses that can sometimes be difficult to mitigate using thermal postprocessing techniques. This article highlights the outstanding issues in Ni-based superalloys AM processing, with special emphasis on defect formation mechanisms, process optimization, and residual stress development.

Keywords

metalmicrostructureNitexture
Type
Research Article
Information
MRS Bulletin , Volume 41 , Issue 10: Metallic materials for 3D printing , October 2016 , pp. 758 - 764
Copyright
Copyright © Materials Research Society 2016 

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