Dispersoid coarsening and slag formation during melt-based additive manufacturing of MA754

Stubbs, Timothy; Hou, Roger; Leonard, Donovan N.; DeBeer-Schmitt, Lisa; Zhu, Yuman; Cordero, Zachary C.; Huang, Aijun

doi:10.1016/j.addlet.2024.100195

Title: Dispersoid coarsening and slag formation during melt-based additive manufacturing of MA754

Journal Article · Mon Apr 01 00:00:00 EDT 2024 · Additive Manufacturing Letters

DOI:https://doi.org/10.1016/j.addlet.2024.100195· OSTI ID:2301738

Stubbs, Timothy; Hou, Roger; Leonard, Donovan N.; DeBeer-Schmitt, Lisa; Zhu, Yuman;

; Huang, Aijun

We have assessed the structural evolution and dispersoid coarsening behaviors of the oxide dispersion-strengthened superalloy MA754 during two different melt-based additive manufacturing techniques – metal laser powder bed fusion (PBF-LB/M) and directed energy deposition (DED). The mechanically alloyed MA754 powder posed challenges for both processes due to its irregular flaky morphology and large particle size. Successful consolidation with PBF-LB/M required increasing the layer height, decreasing the scanning speed, and increasing the laser power relative to typical Ni superalloy printing parameters. The resulting materials contained residual porosity and large Y-Al-oxide slag inclusions which formed in situ. The more prolonged thermal excursion during DED resulted in even larger, mm-scale slag inclusions, which spanned several build layers. In both PBF-LB/M and DED, these inclusions grew at the expense of nanoscale dispersoids, depleting the material of this strengthening phase. These observations motivate alternative approaches for preparing dispersion-strengthened powder feedstocks besides mechanical alloying and highlight the deleterious effects of Al microalloying on dispersoid stability and structure.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF); US Department of the Navy, Office of Naval Research (ONR); Australian Research Council (ARC)

Grant/Contract Number:: AC05-00OR22725; N00014-22-1-2036; LE0882821; LE110100223

OSTI ID:: 2301738

Alternate ID(s):: OSTI ID: 2283840

Journal Information:: Additive Manufacturing Letters, Journal Name: Additive Manufacturing Letters Vol. 9 Journal Issue: C; ISSN 2772-3690

Publisher:: ElsevierCopyright Statement

Country of Publication:: Netherlands

Language:: English

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