Mechanism of heat affected zone cracking in Ni-based superalloy DZ125L fabricated by laser 3D printing technique

Li, Yao; Chen, Kai; Tamura, Nobumichi

doi:10.1016/j.matdes.2018.04.032

Title: Mechanism of heat affected zone cracking in Ni-based superalloy DZ125L fabricated by laser 3D printing technique

Journal Article · Sat Apr 14 00:00:00 EDT 2018 · Materials & Design

DOI:https://doi.org/10.1016/j.matdes.2018.04.032· OSTI ID:1439246

Li, Yao ^[1];

^[2]; Tamura, Nobumichi ^[3]

Xi'an Jiaotong University (China); Lawrence Berkeley National Laboratory (LBNL), Berkeley, CA (United States). Advanced Light Source (ALS)
Xi'an Jiaotong University (China)
Lawrence Berkeley National Laboratory (LBNL), Berkeley, CA (United States). Advanced Light Source (ALS)

Laser 3D printing is a promising technique to repair damaged Ni-based superalloy components. However, the occurrence of heat affected zone (HAZ) cracking severely limits its applicability. In this paper, we unravel the cracking mechanism by studying the element, phase, defect, and strain distribution around an intergranular crack that initiated from the primary HAZ. Using synchrotron X-ray Laue microdiffraction, we measured high tensile strain/stress transverse to the building direction in both the primary HAZ and the cladding layers, as well as high-density dislocations, which resulted from the thermal contraction and rapid precipitation of γ' phase. The crack initiated because the transverse tensile strain/stress tore up the liquid film formed by the low-melting point preexisting phases in the primary HAZ, such as γ/γ' eutectics and coarse γ' precipitates. The incoherent carbide particles were frequently observed near the crack root as local strain concentrators. In the cladding layers, micro-segregation could not be completely avoided, thus the hot crack continued to propagate over several layers with the assistance of the transverse tensile stress. Finally, our investigations provide a useful guideline for the optimization of the 3D printing process to repair Ni-based superalloys with high susceptibility to hot cracking.

View Accepted Manuscript (DOE)

Cite

Export

Save

Research Organization:: Lawrence Berkeley National Lab. (LBNL), Berkeley, CA (United States)

Sponsoring Organization:: USDOE Office of Science (SC); National Natural Science Foundation of China (NSFC); National Key Research and Development Program (China); National Basic Research Program of China

Grant/Contract Number:: AC02-05CH11231; 51671154; 51405507; 2016YFB0700404; 2015CB057400

OSTI ID:: 1439246

Journal Information:: Materials & Design, Vol. 150; ISSN 0264-1275

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (47)

Alloy design for aircraft engines Pollock, Tresa M. Nature Materials, Vol. 15, Issue 8 https://doi.org/10.1038/nmat4709	journal	July 2016
Nickel-Based Superalloys for Advanced Turbine Engines: Chemistry, Microstructure and Properties Pollock, Tresa M.; Tin, Sammy Journal of Propulsion and Power, Vol. 22, Issue 2 https://doi.org/10.2514/1.18239	journal	March 2006
High thermal gradient directional solidification and its application in the processing of nickel-based superalloys Liu, Lin; Huang, Taiwen; Qu, Min Journal of Materials Processing Technology, Vol. 210, Issue 1 https://doi.org/10.1016/j.jmatprotec.2009.07.022	journal	January 2010
Study of the fusion zone and heat-affected zone microstructures in tungsten inert gas-welded INCONEL 738LC superalloy Ojo, O. A.; Richards, N. L.; Chaturvedi, M. C. Metallurgical and Materials Transactions A, Vol. 37, Issue 2 https://doi.org/10.1007/s11661-006-0013-2	journal	February 2006
Characterization of heat affected zone liquation cracking in laser additive manufacturing of Inconel 718 Chen, Yuan; Zhang, Ke; Huang, Jian Materials & Design, Vol. 90 https://doi.org/10.1016/j.matdes.2015.10.155	journal	January 2016
The precipitation of topologically close-packed phases in rhenium-containing superalloys Rae, C. M. F.; Reed, R. C. Acta Materialia, Vol. 49, Issue 19 https://doi.org/10.1016/S1359-6454(01)00265-8	journal	November 2001
Statistical study of ductility-dip cracking induced plastic deformation in polycrystalline laser 3D printed Ni-based superalloy Qian, Dan; Xue, Jiawei; Zhang, Anfeng Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/s41598-017-03051-x	journal	June 2017
Boundary liquation and interface cracking characterization in laser deposition of Inconel 738 on directionally solidified Ni-based superalloy Zhong, Minlin; Sun, Hongqing; Liu, Wenjin Scripta Materialia, Vol. 53, Issue 2 https://doi.org/10.1016/j.scriptamat.2005.03.047	journal	July 2005
Hot cracking in laser welding of Hastelloy X with pulsed Nd:YAG and continuous wave fiber lasers Pakniat, M.; Ghaini, F. Malek; Torkamany, M. J. Materials & Design, Vol. 106 https://doi.org/10.1016/j.matdes.2016.05.124	journal	September 2016
Epitaxial laser metal forming: analysis of microstructure formation Gäumann, M.; Henry, S.; Cléton, F. Materials Science and Engineering: A, Vol. 271, Issue 1-2 https://doi.org/10.1016/S0921-5093(99)00202-6	journal	November 1999
Hardness and microstructural inhomogeneity at the epitaxial interface of laser 3D-printed Ni-based superalloy Qian, Dan; Zhang, Anfeng; Zhu, Jianxue Applied Physics Letters, Vol. 109, Issue 10 https://doi.org/10.1063/1.4962485	journal	September 2016
A synchrotron study of microstructure gradient in laser additively formed epitaxial Ni-based superalloy Xue, Jiawei; Zhang, Anfeng; Li, Yao Scientific Reports, Vol. 5, Issue 1 https://doi.org/10.1038/srep14903	journal	October 2015
Solidification path of single-crystal nickel-base superalloys with minor carbon additions under laser rapid directional solidification conditions Liang, Yao-Jian; Li, Jia; Li, An Scripta Materialia, Vol. 127 https://doi.org/10.1016/j.scriptamat.2016.08.039	journal	January 2017
A synchrotron study of defect and strain inhomogeneity in laser-assisted three-dimensionally-printed Ni-based superalloy Li, Yao; Qian, Dan; Xue, Jiawei Applied Physics Letters, Vol. 107, Issue 18 https://doi.org/10.1063/1.4934839	journal	November 2015
Preliminary investigation on distribution of residual stress generated by the selective laser melting process Casavola, C.; Campanelli, S. L.; Pappalettere, C. The Journal of Strain Analysis for Engineering Design, Vol. 44, Issue 1 https://doi.org/10.1243/03093247JSA464	journal	December 2008
Investigation on multi-track multi-layer epitaxial growth of columnar crystal in direct laser forming Do, XuanTuoi; Li, Dichen; Zhang, Anfeng Journal of Laser Applications, Vol. 25, Issue 1 https://doi.org/10.2351/1.4788595	journal	February 2013
Effect of tube-electrode inner diameter on electrochemical discharge machining of nickel-based superalloy Zhang, Yan; Xu, Zhengyang; Xing, Jun Chinese Journal of Aeronautics, Vol. 29, Issue 4 https://doi.org/10.1016/j.cja.2015.12.016	journal	August 2016
Single-crystal laser deposition of superalloys: processing–microstructure maps Gäumann, M.; Bezençon, C.; Canalis, P. Acta Materialia, Vol. 49, Issue 6 https://doi.org/10.1016/S1359-6454(00)00367-0	journal	April 2001
Repair of directionally solidified superalloy GTD-111 by laser-engineered net shaping Li, Leijun Journal of Materials Science, Vol. 41, Issue 23 https://doi.org/10.1007/s10853-006-0948-0	journal	December 2006
Repair and manufacturing of single crystal Ni-based superalloys components by laser powder deposition—A review Vilar, R.; Almeida, A. Journal of Laser Applications, Vol. 27, Issue S1 https://doi.org/10.2351/1.4862697	journal	February 2015
Reduction of micro-cracking in nickel superalloys processed by Selective Laser Melting: A fundamental alloy design approach Harrison, Neil J.; Todd, Iain; Mumtaz, Kamran Acta Materialia, Vol. 94 https://doi.org/10.1016/j.actamat.2015.04.035	journal	August 2015
A dedicated superbend x-ray microdiffraction beamline for materials, geo-, and environmental sciences at the advanced light source Kunz, Martin; Tamura, Nobumichi; Chen, Kai Review of Scientific Instruments, Vol. 80, Issue 3 https://doi.org/10.1063/1.3096295	journal	March 2009
Automated indexing for texture and strain measurement with broad-bandpass x-ray microbeams Chung, Jin-Seok; Ice, Gene E. Journal of Applied Physics, Vol. 86, Issue 9 https://doi.org/10.1063/1.371507	journal	November 1999
A peak position comparison method for high-speed quantitative Laue microdiffraction data processing Kou, Jiawei; Chen, Kai; Tamura, Nobumichi Scripta Materialia, Vol. 143 https://doi.org/10.1016/j.scriptamat.2017.09.005	journal	January 2018
A look-up table based approach to characterize crystal twinning for synchrotron X-ray Laue microdiffraction scans Li, Yao; Wan, Liang; Chen, Kai Journal of Applied Crystallography, Vol. 48, Issue 3 https://doi.org/10.1107/S1600576715004896	journal	April 2015
Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing Roehling, Tien T.; Wu, Sheldon S. Q.; Khairallah, Saad A. Acta Materialia, Vol. 128 https://doi.org/10.1016/j.actamat.2017.02.025	journal	April 2017
Formation of multimodal size distributions of γ′ in a nickel-base superalloy during interrupted continuous cooling Sarosi, P. M.; Wang, B.; Simmons, J. P. Scripta Materialia, Vol. 57, Issue 8 https://doi.org/10.1016/j.scriptamat.2007.06.014	journal	October 2007
Coarsening kinetics of γ′ precipitates in the commercial nickel base Superalloy René 88 DT Tiley, J.; Viswanathan, G. B.; Srinivasan, R. Acta Materialia, Vol. 57, Issue 8 https://doi.org/10.1016/j.actamat.2009.02.010	journal	May 2009
The influence of cooling rate from temperatures above the γ′ solvus on morphology, mismatch and hardness in advanced polycrystalline nickel-base superalloys Mitchell, R. J.; Preuss, M. Materials Science and Engineering: A, Vol. 473, Issue 1-2 https://doi.org/10.1016/j.msea.2007.04.098	journal	January 2008
Contribution of constitutional liquation of gamma prime precipitate to weld HAZ cracking of cast Inconel 738 superalloy Ojo, O. A.; Richards, N. L.; Chaturvedi, M. C. Scripta Materialia, Vol. 50, Issue 5 https://doi.org/10.1016/j.scriptamat.2003.11.025	journal	March 2004
Microstructure and mechanical properties of rapid directionally solidified Ni-base superalloy Rene′41 by laser melting deposition manufacturing Li, J.; Wang, H. M. Materials Science and Engineering: A, Vol. 527, Issue 18-19 https://doi.org/10.1016/j.msea.2010.04.062	journal	July 2010
Hot cracking mechanism affecting a non-weldable Ni-based superalloy produced by selective electron Beam Melting Chauvet, Edouard; Kontis, Paraskevas; Jägle, Eric A. Acta Materialia, Vol. 142 https://doi.org/10.1016/j.actamat.2017.09.047	journal	January 2018
Hydrogen assisted crack initiation and propagation in a nickel-based superalloy Zhang, Zhenbo; Obasi, Gideon; Morana, Roberto Acta Materialia, Vol. 113 https://doi.org/10.1016/j.actamat.2016.05.003	journal	July 2016
Using JMatPro to model materials properties and behavior Saunders, N.; Guo, U. K. Z.; Li, X. JOM, Vol. 55, Issue 12 https://doi.org/10.1007/s11837-003-0013-2	journal	December 2003
The kinetics of precipitation from supersaturated solid solutions Lifshitz, I. M.; Slyozov, V. V. Journal of Physics and Chemistry of Solids, Vol. 19, Issue 1-2 https://doi.org/10.1016/0022-3697(61)90054-3	journal	April 1961
Last-stage solidification of alloys: Theoretical model of dendrite-arm and grain coalescence Rappaz, M.; Jacot, A.; Boettinger, W. J. Metallurgical and Materials Transactions A, Vol. 34, Issue 3 https://doi.org/10.1007/s11661-003-0083-3	journal	March 2003
Solidification cracking of superalloy single- and bi-crystals Wang, N.; Mokadem, S.; Rappaz, M. Acta Materialia, Vol. 52, Issue 11 https://doi.org/10.1016/j.actamat.2004.03.047	journal	June 2004
The influence of grain boundary angle on the hot cracking of single crystal superalloy DD6 Rong, P.; Wang, N.; Wang, L. Journal of Alloys and Compounds, Vol. 676 https://doi.org/10.1016/j.jallcom.2016.03.164	journal	August 2016
Unraveling submicron-scale mechanical heterogeneity by three-dimensional X-ray microdiffraction Li, Runguang; Xie, Qingge; Wang, Yan-Dong Proceedings of the National Academy of Sciences, Vol. 115, Issue 3 https://doi.org/10.1073/pnas.1711994115	journal	December 2017
Microstructure and yield strength of SLM-fabricated CM247LC Ni-Superalloy Wang, Xiqian; Carter, Luke N.; Pang, Bo Acta Materialia, Vol. 128 https://doi.org/10.1016/j.actamat.2017.02.007	journal	April 2017
The grain boundary microstructures of the base and modified RR 2072 bicrystal superalloys and their effects on the creep properties Chen, Q.; Jones, C.; Knowles, D. Materials Science and Engineering A, Vol. 385, Issue 1-2 https://doi.org/10.1016/S0921-5093(04)00905-0	journal	November 2004
The formation of precipitate free zones along grain boundaries in a superalloy and the ensuing effects on its plastic deformation Krol, Thorsten; Baither, Dietmar; Nembach, Eckhard Acta Materialia, Vol. 52, Issue 7 https://doi.org/10.1016/j.actamat.2004.01.011	journal	April 2004
TEM observation of the heat-affected zone in electron beam welded superalloy Inconel 713C Lachowicz, Maciej; Dudziński, Włodzimierz; Podrez-Radziszewska, Marzena Materials Characterization, Vol. 59, Issue 5 https://doi.org/10.1016/j.matchar.2007.04.010	journal	May 2008
Analysis of laser beam weldability of Inconel 738 superalloy Egbewande, A. T.; Buckson, R. A.; Ojo, O. A. Materials Characterization, Vol. 61, Issue 5 https://doi.org/10.1016/j.matchar.2010.02.016	journal	May 2010
Microstructural characteristics and mechanical properties of laser solid formed K465 superalloy Li, Qiuge; Lin, Xin; Liu, Fenggang Materials Science and Engineering: A, Vol. 700 https://doi.org/10.1016/j.msea.2017.05.064	journal	July 2017
Microstructure of the Nickel-Base Superalloy CMSX-4 Fabricated by Selective Electron Beam Melting Ramsperger, Markus; Singer, Robert F.; Körner, Carolin Metallurgical and Materials Transactions A, Vol. 47, Issue 3 https://doi.org/10.1007/s11661-015-3300-y	journal	January 2016
Microstructure and tensile properties of superalloy IN100 fabricated by micro-laser aided additive manufacturing Bi, Guijun; Sun, Chen-Nan; Chen, Hui-chi Materials & Design, Vol. 60 https://doi.org/10.1016/j.matdes.2014.04.020	journal	August 2014

Similar Records

Hardness and microstructural inhomogeneity at the epitaxial interface of laser 3D-printed Ni-based superalloy

Journal Article · Fri Sep 09 00:00:00 EDT 2016 · Applied Physics Letters · OSTI ID:1439246

Qian, Dan; Zhang, Anfeng; Zhu, Jianxue; +7 more

Statistical study of ductility-dip cracking induced plastic deformation in polycrystalline laser 3D printed Ni-based superalloy

Journal Article · Tue Jun 06 00:00:00 EDT 2017 · Scientific Reports · OSTI ID:1439246

Qian, Dan; Xue, Jiawei; Zhang, Anfeng; +4 more

Rafting-Enabled Recovery Avoids Recrystallization in 3D-Printing-Repaired Single-Crystal Superalloys

Journal Article · Thu Feb 20 00:00:00 EST 2020 · Advanced Materials · OSTI ID:1439246

Chen, Kai; Huang, Runqiu; Li, Yao; +6 more

Related Subjects

36 MATERIALS SCIENCE
HAZ cracking
laser 3D printing
Ni-based superalloy
residual strain/stress
synchrotron X-ray microdiffraction

Title: Mechanism of heat affected zone cracking in Ni-based superalloy DZ125L fabricated by laser 3D printing technique

Citation Formats

References (47)

Similar Records

Related Subjects