A Review on the Evolution Mechanisms and Regulation Strategies of Secondary Phases in Laser Powder Bed Fusion Nickel-Based Superalloys
Received date: 2025-07-29
Revised date: 2025-09-19
Online published: 2026-01-09
Supported by
National Natural Science Foundation of China(52071205);Key Laboratory of Solidification Te-chnology Open Project(SKLSP202214)
Laser powder bed fusion (LPBF) offers high forming precision and the ability to manufacture complex structures, providing a new paradigm for the microstructural design of nickel-based superalloys. However, the rapid cooling and interlayer reheating inherent to LPBF lead to significant deviations in the evolution of secondary phases compared with traditional processes. This study systematically reviews the formation and evolution mechanisms of various secondary phases (γ′ phase, γ″ phase, topologically close-packed (TCP) phase, MC/M23C6 carbides, and dispersed oxides) in LPBF-fabricated nickel-based alloys, and establishes a causal framework linking process parameters, melt pool behavior, solidification substructure, and precipitation. The study reveals that nonequilibrium segregation and cyclic thermal history induce dissolution, reprecipitation, coarsening sequences, and a precipitation gradient along the build direction. By integrating experimental, heat treatment, and multiscale simulation results, a heat treatment window is identified to stabilize γ′/γ″ phase and suppress Laves/δ/TCP phases. The contributions of carbides and oxides to grain boundary pinning and high-temperature stability, coupled with the risks of embrittlement associated with excessive coarsening, are discussed. The synergistic secondary effects of γ′/γ″ phase on creep and fatigue performance, along with the service risks arising from the transformation of γ″ phase into δ phase, are also elucidated. Furthermore, the cooperative effects of hot isostatic pressing, aging, and scanning strategies on precipitation homogenization and defect mitigation are examined. Finally, key challenges and future development paths in multiphase cooperative control, multiscale prediction, and integrated process-microstructure-property design are proposed.
PENG Wangjun , WANG Changhe , DU Dafan , DONG Anping , CHEN Biao , SUN Baode . A Review on the Evolution Mechanisms and Regulation Strategies of Secondary Phases in Laser Powder Bed Fusion Nickel-Based Superalloys[J]. Acta Metall Sin, 2026 , 62(7) : 1147 -1162 . DOI: 10.11900/0412.1961.2025.00209
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