Microstructure and mechanical properties of nickel based superalloy IN718 produced by rapid prototyping with electron beam melting (EBM)

Abstract

A nickel alloy of a composition similar to that of the nickel based superalloy Inconel alloy 718 (IN718) was produced with the electron beam melting (EBM) process developed by Arcam AB. The microstructures of the as processed and heat treated material are similar to that of conventionally produced IN718, except that the EBM material showed some porosity and the δ phase did not dissolve during the solution heat treatment because the temperature of 1000°C apparently was too low. Mechanical testing of the layer structured material, parallel and perpendicular to the built layers, revealed sufficient strength in both directions. However, it showed only limited elongation when tested perpendicular to the built layers due to local agglomerations of pores. Otherwise, data for the hardness, Young’s modulus, 0·2% yield tensile strength and ultimate tensile strength match those recommended for IN718.     

Microstructure and mechanical properties in the TLP joint of FeCoNiTiAl and Inconel 718 alloys using BNi2 filler

High entropy alloy(HEA) of Fe Co Ni Ti Al and Inconel 718 superalloy were firstly transient liquid phase(TLP) bonded by BNi2 filler due to the diffusion of Si and B in the filler to the base metals. The effects of bonding time on microstructure evolution and mechanical properties of the TLP joints were investigated.Owing to the complete isothermal solidification of the joints bonded for 30 min 120 min at 1100°C,no athermally solidified zones(ASZs) formed by eutectic phases were observed in the welded zone. Thus the TLP joints were only composed by the isothermally solidified zone(ISZ) and two diffusion affected zone(DAZ) adjacent to the dissimilar base metals and the negative effect of the ASZ on joint properties can be avoided. In addition, the increase of the bonding time can also make the Ti B2 borides precipitated in the DAZ near HEA and the brittle borides or carbides in the DAZ near IN718 alloy decrease and reduce the possibility of the stress concentration happened in the joints under loading. Therefore, the highest shear strength(632.1 MPa) of the TLP joints was obtained at 1100°C for 120 min, which was higher than that of the joint bonded for 30 min, 404.2 MPa. Furthermore, the extension of the bonding time made the fracture mechanism of the joint be transformed from the intergranular fracture to the transgranular fracture. However, as the brittle borides in the DAZ near IN718 can not be eliminated completely and refining of grains also happened in such region, all the TLP joints fractured inner the DAZ near IN718 alloy.     

Powder bed binder jet 3D printing of Inconel 718: Densification,microstructural evolution and challenges☆

Traditional manufacturing of Inconel 718 components from castings and thermomechanical processing routes involve extensive post processing and machining to attain the desired geometry. Additive manufacturing (AM) technologies including direct energy deposition (DED), selective laser melting (SLM), electron beam melting (EBM) and binder jet 3D printing (BJ3DP) can minimize scrap generation and reduce lead times. While there is extensive literature on the use of melting and solidification based AM technologies, there has been limited research on the use of binder jet 3D printing. In this paper, a brief review on binder jet additive manufacturing of Inconel 718 is presented. In addition, existing knowledge on sintering of Inconel 718 has been extended to binder jet 3D printing. We found that supersolidus liquid phase sintering (SLPS) is necessary to achieve full densification of Inconel 718. SLPS is sensitive to the feedstock chemistry that has a strong influence on the liquid volume fraction at the processing temperature. Based on these results, we discuss an empirical framework to determine the role of powder particle size and liquid volume fraction on sintering kinetics. The role of powder packing factor and binder saturation on microstructural evolution is discussed. The current challenges in the use of BJ3DP for fabrication of Inconel 718, as well as, extension to other metal systems, are presented.     

Influence of Ti content on microstructure,mechanical properties and castability of directionally solidified superalloy DZ125L

Directionally solidified DZ125L alloys of various Ti content were developed by low segregation technology. The microstructure, mechanical properties and castability of directionally solidified superalloy DZ125L were investigated. With decreasing Ti content in DZ125L alloy, the size, volume fraction and separation temperature of γ′ decreased. While the tensile strength and rupture life of directional solidified cylindrical samples is also obviously decreased. Lowering Ti content in alloy resulted in free hot cracking casting blades. Compared with IN792 alloy, DZ125L alloy needs much lower Ti/Ta ratio to achieve good castability.     

Inconel 600及Inconel 718合金晶界偏聚研究进展

高温合金中的溶质晶界偏聚是影响合金多方面性能的重要因素.以高温合金Inconel 600和Inconel718为研究对象,总结了合金中溶质晶界偏聚的研究现状,并对已有的研究成果进行了深入分析,结果发现:溶质在Inconel 600合金中的偏聚规律对舍金性能的影响还需要进一步研究晶界偏聚特性、基本物理参量以及晶间腐蚀抗力的作用;溶质在Inconel 718合金中的晶界偏聚对合金性能的影响依然有待于进一步研究其作用机理、偏聚动力学和共偏聚特性.同时,指出今后高温合金中溶质晶界偏聚的研究方向为溶质晶界偏聚动力学以及溶质问晶界共偏聚行为.     

Directional Solidification of TiAl‐based Alloys and Properties of Directionally Solidified Ingots

The mechanical properties of TiAl‐based alloys with lamellar microstructure are extremely anisotropic. However, if the lamellar microstructure can be aligned parallel to the growth direction, the resulting material should possess a good combination of mechanical properties. Unfortunately, simple casting operations often lead to a solidification texture with the lamellar boundaries perpendicular to the heat flow direction. This difficulty can be overcome by directionally solidifying TiAl‐based alloys. We have been performing directional solidification experiments with and without using a seeding technique. The current status of directional solidification of TiAl‐based alloys is reviewed.     

Developments of cast superalloys and technology for gas turbine blades in BIAM

Since 1960's many important subjects relating to cast turbine blades including alloy developments, directional solidification (DS) and single crystal (SC) technique and casting technology for blades have been performed with great successes in Beijing Institute of Aeronautical Materials (BIAM) in order to meet the requirements for developing new aero-engines in China.Abbreviations CC conventional cast - DS directional solidification - FC fine grain cast - SC single crystal     

Interfacial reactions between lithium silicate glass-ceramics and Ni-based superalloys and the effect of heat treatment at elevated temperatures

Two lithium silicate glasses (S- and BPS-glass) were sealed to four different Ni-based superalloys (Inconel 600, Inconel 718, Haynes 230, and Hastelloy C-276) and the effects of long-term heating at 700–900°C on the chemical, microstructural, and mechanical properties of sealed interfaces were studied. The presence of a small amount of ZnO in the BPS-glass leads to the formation of a thin interfacial second phase layer and a less rough alloy interface compared to the ZnO-free S-glass. Inconel 718 was found to be the most reactive of the alloys, with Cr and Nb diffusing into the glass and forming a coarse glass-ceramic microstructure at the interface. Heat treatment of all the reaction assemblies at 900°C for 100 h in air resulted in degradation of the seals and their spontaneous failure. Heat treatments at 700 or 800°C did not cause any interfacial coarsening in BPS sealed to Inconel 600, Haynes 230, and Hastelloy C-276 alloys and did not alter the bond strength of Haynes 230 bars, sealed with a thin layer of BPS-glass, demonstrating the potential of these material combinations for applications up to 800°C.     

Microstructure of the oxide ceramics/Inconel 713C interface

Nickel-based refractory alloys are used in the aerospace industry as materials for the production of engine turbine blades obtained by the casting method. Both casting process and surface quality of the ceramic mould have a significant influence on product properties. Current research involved the investigation of interactions between oxide ceramics, forming the basic material of casting moulds and crystallisers, and Inconel 713C nickel superalloy. The wettability of ceramics by Inconel 713C was tested for the three types of materials at temperatures commonly used in the directional casting of this alloy. The oxide ceramics/Inconel 713C interfaces were examined by SEM to reveal the microstructure of phase boundary and assess the degree of degradation of the casting mould ceramic coating.     

Application of high temperature DSC technique to nickel based superalloys

Heat capacity is a critical input parameter in mathematical models of solidification and casting. It appears in its own right, and is required for the extraction of thermal conductivity from thermal diffusivity data. It also provides a measure of the latent heat associated with changes of phase, and the precipitation or dissolution of precipitates. Calorimetry is a well-established technique and is used to solve a wide range of materials problems such as studying precipitation or phase changes in alloy systems, and the kinetics of these phase transformations. The quality and range of data that can be obtained will be demonstrated by applying it to nickel base superalloys.This paper discusses important aspects of the measurement including control of the atmosphere, suitable reference materials for temperature and enthalpy calibration, size of the sample and the rate of heating and cooling. The optimised DSC technique was used to investigate the properties of two nickel based superalloys (CMSX4 and IN738LC), comparing the results with previous values and determining sources of error in the method.     

Mechanical properties of conventionally cast,directionally solidified,and single-crystal superalloys

Abstract

In this paper the authors compare the creep and low-cycle fatigue properties of conventional, directionally solidified, and single-crystal castings produced from nickel-base superalloys. A brief historical review describes the reasons for the evolution from wrought to cast product through directionally solidified to modern single-crystal (‘monocrystal’) castings. The influence of microstructural variations produced by the casting conditions, such as porosity and grain size, on creep and low-cycle fatigue properties are illustrated. The important aspects of postsolidification heat treatment, hot isostatic pressing, and the damaging effects of impurities are described for conventional castings. The results of controlling the microstructures produced by directional solidification especially by high temperature gradient solidification are demonstrated by comparing the creep properties of directionally solidified materials with those of the conventionally cast alloys in long-term tests. The creep and low-cycle fatigue properties depend on the stress direction relative to the crystallographic directions of the material for both directionally solidified and single-crystal castings. For single crystals, individual alloys show variable dependences of properties on the crystallographic directions. Directionally solidified materials show advantages in thin sections and are less sensitive to the effects of impurities compared to conventional castings.

MST/329     

镍基单晶高温合金凝固缺陷研究进展

镍基单晶高温合金的凝固缺陷对其力学性能有很大的影响,减少和控制凝固缺陷对提高合金性能和降低成本具有重要意义。综述了镍基单晶高温合金定向凝固过程中可能出现的几个重要缺陷,包括缩松、雀斑、晶体取向的偏离和杂晶,重点讨论了这些缺陷的特点和产生的机理,并从合金成分、工艺参数、铸件结构等方面分析了凝固缺陷的影响因素,指出了减少单晶高温合金凝固缺陷的措施。     

Effect of boron and zirconium on directional solidification behaviour and segregation of DS IN738 superalloy

The effect of boron and zirconium on the directional solidification behaviour and segregation of IN738 superalloy has been studied. It was found that additions of boron and zirconium enlarge the solidus-liquidus temperature interval and increase the amount of residual melt during solidification. Boron gives the alloy a tendency to form developed dendrites, while zirconium enhances a cellular solidified structure. Both boron and zirconium are shown to be rejected to the residual melt during solidification, and shown to change the segregation of alloying elements by interaction.     

Effects of Loading Waveform and Stress Field on High Temperature Fatigue Crack Growth of Alloy 718

High temperature fatigue in nickel‐base superalloys for aero‐engine applications requires consideration of cycle‐ and time‐dependent phenomena. For waveforms with dwells and/or low frequencies crack growth rates may be significantly accelerated up to the point of fully time‐dependent crack growth. In the paper, the interaction of fatigue (cycle‐dependent) and dwell (time‐dependent) crack growth is addressed using a broad database for IN 718 tested at 600°C. Waveforms with dwells at as well as below maximum load levels are applied to standard CT and CC specimens and blunt notched specimens. It is demonstrated that both the level of dwells with respect to the maximum load level within a cycle as well as the specific conditions at the notch root considerably affect the significance of dwells for fatigue crack growth.     

Effect of Phosphorus on Stress Rupture Properties of GH4133 Ni—Base Superalloy

The effect of phosphorus on the stress rupture property of GH4133 alloy has been investigated and is compared with that of IN718 alloy. The GH4133 alloy is crept by dislocation movement. Phosphorus has a tendency to prolong the rupture life of some wrought superalloys by inhibiting the dislocation movement. If the phosphorus addition is too high, its effect on impairing the grain boundary cohesion overwhelms that on inhibiting the dislocation movement,and the life of the GH4133 alloy can be shortened. The two functions of inhibiting the dislocation movement and impairing the grain boundary cohesion determine that the optimum phosphorus content in the GH4133 alloy is around 0.011 wt pct. Phosphorus exhibits a greater effect on prolonging the rupture life of IN718 alloy than that of GH4133 alloy. The two alloys are crept by different mechanisms. The intergranular phosphorus-bearing phase is precipitated in the IN718 alloy, while not in the GH4133 alloy. The precipitation of the phosphorus bearing phase can balance the phosphorus segregation at the grain boundaries and allows a more remarkable effect of phosphorus on extending the rupture life of IN718 alloy.     

Brazing of reaction-bonded silicon carbide and Inconel 600 with an iron-based alloy

The objective of the present work was to join reaction-bonded silicon carbide to Inconel 600 (IN600, a nickel-based superalloy) for use in high temperature applications by brazing with an Fe-20wt% alloy. This joining method resulted in the molten filler metal reacting with the IN600 to form a Ni-Fe-Si solution, which in turn formed a liquid with the free silicon phase of the RBSC. This liquid reacted vigorously with the SiC component of the RBSC to form low melting point phases in both starting materials and chromium carbides at the metal-ceramic interface. By using solution thermodynamics, it was shown that a Ni-Fe-Si liquid with equimolar nickel and iron contents and silicon content of less than 30 at% Si will decompose -SiC at the experimental brazing temperatures; it was also shown that these predictions agree with the experimentally observed microstructures and line composition profiles.     

The effect of silicon on the microstructure and segregation of directionally solidified IN738 superalloy

Th e effect of silicon on the microstructure and solidification segregation of directionally solidified IN738 nickel-based superalloy was studied. Directional solidification at various solidification rates and partial directional solidification plus rapid quenching were applied. Metallographican alysis and an electron microp robe were mainly used to observe and measure the micro structure and elemental segregation of the alloy, respectively. It was found that silicon affected the morphology of the liquid-solid interface of the alloy during solidification and gave the alloy a tendency to form well-developed dendrites. The addition of siliconen larged the solid us-liquidus temperature interval. and the solidification rate also greatly influenced the interval. The interval increased with increasing solidification rate. Silicon promoted the precipitation of the γ/γ' eutectic, and also affected its precipit ation temperature. Silicon segregated mainly in interd endritic regions, and promoted the segregation of other elements. All of the effects of silicon on the alloy related to the solidification rate.     

晶粒取向对激光快速凝固形态的影响

研究了一种 Ni 基定向合金激光快速熔凝的结晶形态以及冷却速度对激光熔凝组织的影响。结果表明,激光快速凝固结晶形态强烈地依赖于熔池边界基材的晶粒取向。激光熔区的显微组织尺度与冷却速度有关。     

Joining Between NiAl and Heat Resistant Alloys by Reactive Casting

NiAl is a low‐density and high‐strength structural material that has potential for use at temperatures higher than currently possible with conventional superalloys. However, NiAl is brittle at temperatures below 600 K, which is one of its most significant disadvantages and impedes its practical use as a structural material. A possible way to overcome this problem will be joining of it to ductile structural materials. The authors have recently developed a new technique named “reactive casting,” which enables the superheated liquid of a high‐melting‐point intermetallic compound to be produced without the need of external heating. In this study, they investigate the feasibility of joining between NiAl and heat resistant alloys such as nickel‐base and iron‐base alloys by the reactive casting method.     

镍基高温合金定向凝固过程中雀斑缺陷研究进展

本文简述了近年来定向和单晶镍基高温合金凝固过程中雀斑缺陷的研究进展,具体论述了雀斑缺陷的形成机制以及雀斑的预判模型,并从合金成分、凝固参数(抽拉速率和温度梯度)、凝固界面形态以及试样形状和尺寸等方面分析和论述了这些因素对雀斑缺陷形成的影响,最后对未来镍基高温合金中雀斑缺陷的研究方向进行了探讨和展望。