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Title: Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion

Abstract

Excellent weldability and high temperature stability make Inconel 718 (IN718) one of the most popular alloys to be produced by additive manufacturing. Here in this study, we investigated the effects of laser powder bed fusion (LPBF) parameters on the microstructure and relative density of IN718. The samples were fabricated with independently varied laser power (125 - 350W), laser scan speed (200 - 2200 mm/s), and laser scan rotation (0° - 90°). Archimedes’ method, optical microscopy, and scanning electron microscopy were employed to assess the influence of LPBF parameters on the relative density and microstructure. Optimal processing windows were identified for a wide range of processing parameters and relative density greater than 99.5% was achieved using volumetric energy density between 50 and 100 J/mm3. Microstructural features including melt pool geometry, lack of fusion defect, keyhole porosity, and sub-grain cellular microstructure were examined and quantified to correlate to LPBF parameters. A simple empirical model was postulated to relate relative sample density and LPBF volumetric energy density. Melt pool dimensions were quantitatively measured and compared to estimations based on Rosenthal solution, which yielded a good agreement with the width, but underestimated the depth, particularly at high energy input, due to lack of considerationmore » for keyhole mode. In addition, the sub-grain cellular-dendritic microstructure in the as-built samples was observed to decrease with increasing laser scan speed. Quantification of the sub-micron cellular-dendritic microstructure yielded estimated cooling rate in the order of 105 – 107 K/s.« less

Authors:
 [1];  [1];  [1];  [1];  [1];  [1];  [1];  [2]; ORCiD logo [2];  [2];  [1]
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  1. University of Central Florida, Orlando, FL (United States)
  2. Idaho National Laboratory (INL), Idaho Falls, ID (United States)
Publication Date:
Research Org.:
Idaho National Laboratory (INL), Idaho Falls, ID (United States)
Sponsoring Org.:
USDOE Office of Nuclear Energy (NE)
OSTI Identifier:
1963949
Report Number(s):
INL/JOU-21-65135-Revision-1
Journal ID: ISSN 2192-9262; TRN: US2313184
Grant/Contract Number:  
AC07-05ID14517
Resource Type:
Accepted Manuscript
Journal Name:
Metallography, Microstructure and Analysis
Additional Journal Information:
Journal Volume: 11; Journal Issue: 1; Journal ID: ISSN 2192-9262
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS; additive manufacturing

Citation Formats

Huynh, Thinh, Mehta, Abhishek, Graydon, Kevin, Woo, Jeongmin, Park, Sharon, Hyer, Holden, Zhou, Le, Imholte, D. Devin, Woolstenhulme, Nicolas E., Wachs, Daniel M., and Sohn, Yongho. Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion. United States: N. p., 2022. Web. doi:10.1007/s13632-021-00811-0.
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Huynh, Thinh, Mehta, Abhishek, Graydon, Kevin, Woo, Jeongmin, Park, Sharon, Hyer, Holden, Zhou, Le, Imholte, D. Devin, Woolstenhulme, Nicolas E., Wachs, Daniel M., & Sohn, Yongho. Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion. United States. https://doi.org/10.1007/s13632-021-00811-0
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Huynh, Thinh, Mehta, Abhishek, Graydon, Kevin, Woo, Jeongmin, Park, Sharon, Hyer, Holden, Zhou, Le, Imholte, D. Devin, Woolstenhulme, Nicolas E., Wachs, Daniel M., and Sohn, Yongho. Mon . "Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion". United States. https://doi.org/10.1007/s13632-021-00811-0. https://www.osti.gov/servlets/purl/1963949.
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@article{osti_1963949,
title = {Microstructural Development in Inconel 718 Nickel-Based Superalloy Additively Manufactured by Laser Powder Bed Fusion},
author = {Huynh, Thinh and Mehta, Abhishek and Graydon, Kevin and Woo, Jeongmin and Park, Sharon and Hyer, Holden and Zhou, Le and Imholte, D. Devin and Woolstenhulme, Nicolas E. and Wachs, Daniel M. and Sohn, Yongho},
abstractNote = {Excellent weldability and high temperature stability make Inconel 718 (IN718) one of the most popular alloys to be produced by additive manufacturing. Here in this study, we investigated the effects of laser powder bed fusion (LPBF) parameters on the microstructure and relative density of IN718. The samples were fabricated with independently varied laser power (125 - 350W), laser scan speed (200 - 2200 mm/s), and laser scan rotation (0° - 90°). Archimedes’ method, optical microscopy, and scanning electron microscopy were employed to assess the influence of LPBF parameters on the relative density and microstructure. Optimal processing windows were identified for a wide range of processing parameters and relative density greater than 99.5% was achieved using volumetric energy density between 50 and 100 J/mm3. Microstructural features including melt pool geometry, lack of fusion defect, keyhole porosity, and sub-grain cellular microstructure were examined and quantified to correlate to LPBF parameters. A simple empirical model was postulated to relate relative sample density and LPBF volumetric energy density. Melt pool dimensions were quantitatively measured and compared to estimations based on Rosenthal solution, which yielded a good agreement with the width, but underestimated the depth, particularly at high energy input, due to lack of consideration for keyhole mode. In addition, the sub-grain cellular-dendritic microstructure in the as-built samples was observed to decrease with increasing laser scan speed. Quantification of the sub-micron cellular-dendritic microstructure yielded estimated cooling rate in the order of 105 – 107 K/s.},
doi = {10.1007/s13632-021-00811-0},
journal = {Metallography, Microstructure and Analysis},
number = 1,
volume = 11,
place = {United States},
year = {Mon Jan 10 00:00:00 EST 2022},
month = {Mon Jan 10 00:00:00 EST 2022}
}
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https://doi.org/10.1007/s13632-021-00811-0
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Figures / Tables:

Table 1 Table 1: Composition (wt.%) of IN718 powder feedstock from XEDS and ASTM F3055 - 14.
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