Crack Mechanism and Control Strategy for Ni58Cr23Fe10W5-Ti2Ta1Nb1 Multi-Principal Element Alloy by Selective Laser Melting

doi:10.11900/0412.1961.2024.00086

Acta Metall Sin

2025, Vol. 61

Issue (11): 1703-1714 DOI: 10.11900/0412.1961.2024.00086

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Crack Mechanism and Control Strategy for Ni₅₈Cr₂₃Fe₁₀W₅-Ti₂Ta₁Nb₁ Multi-Principal Element Alloy by Selective Laser Melting

LIN Mei, GUO Bojing, WANG Zhijun, LI Junjie, WANG Lei, WANG Jincheng, HE Feng(

)

State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi'an 710072, China

Cite this article:

LIN Mei, GUO Bojing, WANG Zhijun, LI Junjie, WANG Lei, WANG Jincheng, HE Feng. Crack Mechanism and Control Strategy for Ni₅₈Cr₂₃Fe₁₀W₅-Ti₂Ta₁Nb₁ Multi-Principal Element Alloy by Selective Laser Melting. Acta Metall Sin, 2025, 61(11): 1703-1714.

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Abstract

With the increasing sophistication of laser additive manufacturing technology, the need for high-performance alloys suitable for additive manufacturing has grown. Developing new alloys with excellent mechanical properties and good formability has become a critical direction in the field of additive manufacturing, but severe defect-like cracking remains a major concern. Based on a new design concept from the corners of the phase diagrams to the central region, multi-principal element alloys (MPEAs, i.e., high-entropy alloys) have introduced new opportunities for the development of high-performance additive manufactured alloys. Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ MPEA (containing 0.02%B element, mass fraction) shows great potential for overcoming the severe trade-off between manufacturability and high strength. On the one hand, Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ MPEA has a yield strength of ~1 GPa and an elongation of ~25%, thus its comprehensive performance is superior to that of most existing MPEAs. On the other hand, because of its slower precipitation kinetics than the IN718 alloy, the main strengthening phase ( $γ ″$ ) of MPEA is stable at 800 ^oC, and thus it shows promise for eliminating the cracking of the precipitation-strengthened alloys. However, because Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ MPEA is a newly designed alloy, the effects of multi-principal alloying on its non-equilibrium solidification behavior are unknown, as is the mechanism of this effect, and its cracking behavior under additive manufacturing and corresponding mechanism must be evaluated. This work takes Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ MPEA as the research object and uses selective laser melting (SLM) technology and advanced characterization techniques to investigate the crack formation mechanism and control path of the alloy under different SLM process parameters. The formability of Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ alloy under different SLM process parameters was investigated, and the crack formation mechanism of Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ alloy was revealed. The crack control method was then explored. The results showed that the cracks propagated along the grain boundary of the coarse columnar crystals and preferentially appeared at high-angle grain boundaries (HAGBs). The surface of the cracks presented a smooth and clear dendritic morphology, which is a typical solidification crack. At the terminal stage of solidification, the HAGB regions contain a thin layer of B segregation, which promoted the production of a continuous liquid film, and the liquid film remained stable at HAGB owing to the large grain boundary energy. The residual stress caused by heating/cooling circulation acted on the liquid film and triggered solidification cracking. The relationship between the heat input and the cracking sensitivity was not linear. Cracks cannot be eliminated by simply regulating heat input, and cracks can be suppressed only to a certain extent. The grain boundary density increased, local stress concentration was alleviated, and solidification cracks were successfully eliminated with the addition of TiB₂ nanoparticles.

Key words: selective laser melting solidification crack cracking mechanism high-entropy alloy

Received: 18 March 2024

ZTFLH:

TG146

Fund: National Natural Science Foundation of China(52001266);Fundamental Research Funds for the Central Universities(G2022KY05109);Guangdong Basic and Applied Basic Research Foundation(2023A1515012703);Shanghai “Phosphor” Science Foundation(23YF1450900);Practice and Innovation Funds for Graduate Students of Northwestern Polytechnical University(PF20-23073)

Corresponding Authors: HE Feng, professor, Tel: 18710790457, E-mail: fenghe1991@nwpu.edu.cn

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	LIN Mei
	GUO Bojing
	WANG Zhijun
	LI Junjie
	WANG Lei
	WANG Jincheng
	HE Feng

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https://www.ams.org.cn/EN/10.11900/0412.1961.2024.00086 OR https://www.ams.org.cn/EN/Y2025/V61/I11/1703

Fig.1 Low magnification SEM image of powder and size distribution (inset) (a) and high magnification SEM image and corresponding EDS elemental mapping results of powder (b) of Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ multi-principal element alloy atomized by plasma rotating electrode process

Fig.2 Powder morphologies of TiB₂nanoparticles (a) and mechanical mixing of 1%TiB₂ nanoparticle and Ni₅₈Cr₂₃Fe₁₀- W₅Ti₂Ta₁Nb₁ alloy powder (b), and locally enlarged image of Fig.2b and corresponding EDS elemental mapping results (b1)

Table 1 Designed composition and chemical composition of alloy powder and SLMed sample

Fig.3 Scanning strategy of 67° layer by layer rotation

Fig.4 OM images of SLMed Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ alloy under laser powers (P) of 210 W (a1-d1), 245 W (a2-d2), 280 W (a3-d3), 315 W (a4-d4), and 350 W (a5-d5) and scanning velocities (v) of 1200 mm/s (a1-a5), 1000 mm/s (b1-b5), 800 mm/s (c1-c5), and 600 mm/s (d1-d5)

Fig.5 Effects of process parameters on cracking behavior of SLMed Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁alloy

Fig.6 Crack distribution characteristics of SLMed Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ alloy under volume energy density E_v = 182.3 J/mm³ (P = 350 W, v = 600 mm/s)
(a) grain boundary distribution (The red lines and blue lines denote the high-angle grain boundaries (misorientation angle > 15°) and low-angle grain boundaries (misorientation angle 2°-15°), respectively)
(b) misorientation between grain pairs that are present in Fig.6a

Fig.7 Crack surface SEM images of SLMed Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ alloy under E_v = 54.7 J/mm³ (a), E_v = 82.0 J/mm³ (b), and E_v = 182.3 J/mm³ (c)

Fig.8 Thermodynamic calculations of Ni₅₈Cr₂₃Fe₁₀W₅-Ti₂Ta₁Nb₁ alloy based on equilibrium and Scheil mode conditions (ΔT_Equilibrium—solidification temperature range under equilibrium conditions, ΔT_Scheil—solidification temperature range under Scheil mode conditions)

Fig.9 Atomic fractions of elements in the liquid during the solidification of Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ alloy
(a) Ni, Cr, Fe, W, Ti, Ta, and Nb elements
(b) B element

Fig.10 SEM image of SLMed Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁alloy near a crack and corresponding EDS elemental mapping results

Fig.11 Stress distribution characteristics of SLMed Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁ alloy under E_v = 182.3 J/mm³
(a) kernel average misorientation (KAM) map
(b) inverse pole figure (IPF) (Recrystallized grains are indicated by circles)

Fig.12 Effects of volume energy density (heat input) on the cracking behavior of SLMed Ni₅₈Cr₂₃Fe₁₀-W₅Ti₂Ta₁Nb₁alloy (h—scan spacing)

Fig.13 Solidification microstructures of SLMed Ni₅₈Cr₂₃Fe₁₀W₅Ti₂Ta₁Nb₁alloy at the same process parameters (P = 280 W, v = 1000 mm/s, thickness t = 0.04 mm, h = 0.07 mm) before (a1-d1) and after (a2-d2) adding 1%TiB₂ nanoparticles
(a1, a2) band contrast (BC) maps (b1, b2) IPFs (c1, c2) grain boundary (GB) maps (d1, d2) KAM maps

Fig.14 Melt pool morphology of SLMed Ni₅₈Cr₂₃Fe₁₀-W₅Ti₂Ta₁Nb₁ alloy adding 1%TiB₂ nanoparticles at the process parameters of P = 280 W, v = 1000 mm/s, t = 0.04 mm, h = 0.07 mm

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