Research Progress on the Crack Formation Mechanism and Cracking-Free Design of γ' Phase Strengthened Nickel-Based Superalloys Fabricated by Selective Laser Melting
ZHU Guoliang1,2(), KONG Decheng1,2, ZHOU Wenzhe1,2, HE Jian1,2, DONG Anping1,2, SHU Da1,2, SUN Baode1,2
1.Shanghai Key Laboratory of Advanced High Temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai 200240, China 2.State Key Laboratory of Metal Matrix Composite Materials, Shanghai Jiao Tong University, Shanghai 200240, China
Cite this article:
ZHU Guoliang, KONG Decheng, ZHOU Wenzhe, HE Jian, DONG Anping, SHU Da, SUN Baode. Research Progress on the Crack Formation Mechanism and Cracking-Free Design of γ' Phase Strengthened Nickel-Based Superalloys Fabricated by Selective Laser Melting. Acta Metall Sin, 2023, 59(1): 16-30.
Traditional high-strength nickel-based superalloys have a wide solidification temperature range and high proportion of low melting point eutectic phases, which are prone to cracking during rapid nonequilibrium solidification. The residual stress release and rapid nucleation of γ' precipitate during the post-heat treatment process result in crack formation for high-strength nickel-based superalloys, which limits their application and promotion in the field of additive manufacturing. In this review, the research progress in crack formation mechanism and cracking-free design (printing parameter optimization, post-treatment regulation, and alloying design) of high-strength nickel-based superalloys fabricated via additive manufacturing is presented. Additionally, research prospects related to crack control of additively manufactured high-strength nickel-based superalloys are proposed.
Fig.1 Relationship between the weldability (cracking sensitivity) and alloying elements in nickel-based superalloys (a) Al and Ti elements[9] (b) Al, Ti, Cr, and Co elements[11]
Fig.2 Typical cracking morphologies in selective laser melted CM247LC high-strength nickel-based superalloy (Red rectangle regions indicate the enlarged regions)[22] (a1-a3) solidification cracks (b1-b3) liquidation cracks (c1-c3) solid cracks
Fig.3 Atom probe reconstruction from a random high angle grain boundary in the cracked columnar region of a non-weldable nickel-based superalloy with high aluminum and titanium content (a), one-dimensional composition profiles across the γ'/GB/γ interface as denoted by arrow 1 in Fig.3a (b, c) (GB—grain boundary)[29]
Fig.4 Temperature and time relationship of heat treatment cracking of nickel-based superalloys with different precipitate types (t—time) (a)[41], statistics of crack density after 2 h heat-treatment at different temperatures for selective laser melted CM247LC alloy (b)[42], high temperature plasticizing crack at grain boundary (c)[42], and strain-aged crack (d)[42]
Fig.5 Schematic of residual stress distribution and formation mechanism during selective laser melting (HAZ—heat-affected zone) (a), residual stress distribution on the bulk sample before and after removed from the substrate (b)[51]
Fig.6 Relationship between forming quality and scan velocity for CM247LC (a)[55] and scanning strategy for IN738LC (Insets show the corresponding defects such as cracks and voids) (b)[56] fabricated by selective laser melting
Fig.7 Calculated thermal history (temperature profiles, heating and cooling rates) versus time of the same point under the continuous-wave (a) and pulsed-wave modes (b), and the defect of the selective laser melted IN738LC alloys fabricated under the continuous-wave (c) and pulsed-wave mode (d)[57] (Tmax is the maximum temperature of the molten pool, is minimum cooling rate)
Fig.8 Bottom cracking of samples with different sample heights (h) before and after preheating (a)[60], effect of substrate preheating temperature on crack density and residual stress of high-strength nickel-based superalloy (b)[51]
Fig.9 Morphological characteristics of cracks in the additive manufacturing samples before (a) and after (b) hot isostatic pressing[66], distribution of crack defects on the surface of the samples before (c) and after (d) hot isostatic pressing (Inset in Fig.9d shows the locally enlarged view)[55]
Fig.10 Comparisons of cracks (a, b) and elemental distributions at cracks and grain boundaries (c, d) of IN738LC alloy fabricated by selective laser melting before (a, c) and after (b, d) addition of second phase carbides[69] (BD—building direction, LPBF—laser powder bed fusion. Insets in Figs.10a and b show the locally enlarged views)
Fig.11 Design of crack-free nickel-based superalloys produced by additive manufacturing (a) solidification temperature range and γ' phase content[22] (b) solidification temperature range and creep life[22] (c) solidification temperature range and strain aging crack factor[22] (d) property design comparison of nickel-based superalloys fabricated by additive manufacturing (OAC—oxidation-assisted cracking)[80]
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