Research Progress on Crack Control and Composition Design of <bold>γ′</bold> Phase Strengthened Nickel‑Based Superalloys Suitable for Laser Additive Manufacturing (Invited)

Shujing Shi; Zhuo Li; Chen Yang; Ziheng Zeng; Xu Cheng; Haibo Tang; Huaming Wang

doi:10.3788/CJL231577

Chinese Journal of Lasers, Volume. 51, Issue 10, 1002302(2024)

Research Progress on Crack Control and Composition Design of γ′ Phase Strengthened Nickel‑Based Superalloys Suitable for Laser Additive Manufacturing (Invited)

Shujing Shi¹, Zhuo Li^1,2、*, Chen Yang², Ziheng Zeng², Xu Cheng^1,2, Haibo Tang^1,2, and Huaming Wang^1,2

Author Affiliations

¹Ningbo Institute of Technology, Beihang University, Ningbo 315800, Zhejiang , China

²National Engineering Laboratory of Additive Manufacturing for Large Metallic Components, Beihang University, Beijing 100191, China

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Figures & Tables(17)

Fig. 1. Material‒structure‒performance integrated LAM technology in multifunctional design and manufacturing^[7]

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$Morphology and cracking mechanism of solidification crack in LAM nickel-based superalloys. (a) Correlation between solid phase fraction and solidification cracking index (SCI)[24]; (b) schematic diagram of cracking mechanism[25]; (c) solidification crack in CM247LC alloy[24]; (d) solidification crack in IN939 alloy[24]$

Fig. 2. Morphology and cracking mechanism of solidification crack in LAM nickel-based superalloys. (a) Correlation between solid phase fraction and solidification cracking index (SCI)^[24]; (b) schematic diagram of cracking mechanism^[25]; (c) solidification crack in CM247LC alloy^[24]; (d) solidification crack in IN939 alloy^[24]

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Fig. 3. Morphology and cracking mechanism of liquation crack in LAM nickel-based superalloys. (a) Constitutional liquation^[1,24];

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Fig. 4. Differential scanning calorimetry curves and morphology of ABD-850AM, CM247LC and IN939 alloys^[24]

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Fig. 5. DDC and its relationship with temperature in LAM nickel-based superalloys. (a) Morphology of DDC in IN738 alloy^[34];

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$Calculation and design of formable new γ' phase strengthened nickel-based superalloys. (a) Relationship between SAC risk and Al, Ti+Nb+Ta contents[24]; (b) γ' phase morphology and size in different generations of nickel-based single crystal superalloys[40]; (c) relationship between mole fraction of γ' phase and SAC merit index[24]; (d) relationship between creep life and SAC merit index[24]$

Fig. 6. Calculation and design of formable new γ' phase strengthened nickel-based superalloys. (a) Relationship between SAC risk and Al, Ti+Nb+Ta contents^[24]; (b) γ' phase morphology and size in different generations of nickel-based single crystal superalloys^[40]; (c) relationship between mole fraction of γ' phase and SAC merit index^[24]; (d) relationship between creep life and SAC merit index^[24]

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Fig. 7. Relationship between the integrity of LAM component and process parameters and alloy composition^[9,37]. (a) Defects caused by incompatibility between laser process parameters and alloy composition; (b) influence of composition optimization on solidification characteristics and formability of alloys

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Fig. 8. Inhibitory effect of composition modification on crack in nickel-based superalloys. (a) Mechanism of reduced cracking sensitivity in new γ' phase strengthened MAD542 alloy^[41]; (b) influence of Zr content on crack density, size and quantity of carbide and ΔT of IN738LC alloy^[45]

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Fig. 9. Inhibitory effect of adding nanoparticles on crack in nickel-based superalloys. (a) Influence of 2.5% TiC on grain morphology and solute enrichment in IN738LC alloy^[51]; (b) influence of 0.1% GNPs on grain morphology and dislocation distribution in K418 alloy^[52]

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Fig. 10. Defect control and mechanical properties of LAM IN738LC alloy^[18]. (a) Formability of IN738LC alloy under different laser powers and scanning speeds; (b) LPBF process map of IN738LC alloy; (c) influence of post-processing on tensile properties of as-printed samples at room temperature; (d) jet turbine blade fabricated by LPBF

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Fig. 11. Thermodynamics-guided LAM superalloy design process^[72]. (a) Interdendritic composition segregation measured by APT; (b) influence of partitioning behavior of alloy element on T_solidus; (c) influence of alloy element on driving forces of phase formation, and a schematic diagram of the whole design process

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Fig. 12. Prediction of crack susceptibility in LAM nickel-based superalloy^[76]. (a) Construction process of ML model; (b) fitting performance of ML models on training sets; (c) comprehensive influence of elements on crack susceptibility evaluated by ML prediction model

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Fig. 13. Relationship between composition and formability of nickel-based superalloys. (a) Formability of nickel-based superalloys represented by the contents of Al+Ti and Cr+Co^[38]; (b) composition distribution of formable/unformable superalloys in $\bar{C r}$ ‒ $\bar{A l}$ system

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Fig. 14. Cracking resistance and mechanical properties of MNiHEA alloy^[93]. (a) Relationship between average SCI value and solidification cracking in the last solidification stage; (b) uniaxial tensile engineering stress-strain curves; (c) strengthening and toughening mechanisms of as-built and aged alloys

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Fig. 15. Research on cracking behavior of LAM γ' phase strengthened nickel-based superalloys. (a) Summary of cracks causes and control methods^[66]; (b) comparison of room-temperature tensile properties of representative formable and unformable superalloys before and after crack control^[1]

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Table 1. Effects of elements on the metallurgical performance of γ' phase strengthened nickel-based superalloys^[16]

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Table 1. Effects of elements on the metallurgical performance of γ' phase strengthened nickel-based superalloys^[16]

Alloy element	Metallurgical performance
Co， Cr， Fe， Mo， W， Ta， Re	Solid-solution strengthener
W， Ta， Ti， Mo， Nb， Hf	Carbide form	MC
Cr		M₇C₃
Cr， Mo， W		M₂₃C₆
Mo， W， Nb		M₆C
C， N	Carbonitrides： M（CN）
Al， Ti	γ′-Ni₃ （Al， Ti） phase
Co	Solvus temperature of γ′ phase
Al， Ti， Nb， Ta	Intermetallics
Al， Cr， Y， La， Ce	Oxidation resistance
La， Th	Hot corrosion resistance
Cr， Co， Si	Sulfidation
B， Ta	Creep resistance
B	Rupture strength
B， C， Zr， Hf	Grain refinement
Re	Retard γ′ coarsening

Table 2. Composition and cluster formula analysis of nickel-based superalloys^{[44,82,84-86]}

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Table 2. Composition and cluster formula analysis of nickel-based superalloys^{[44,82,84-86]}

Alloy	Composition	Cluster formula
IN100	Ni_57.6Co_12.6Al_11.1Ti_5.1V_1.1Cr_10.3 Mo₂	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.8}$ $\bar{C r}$ $_{2.1}$
MAR-M247	Ni₆₂Co_10.1Al_12.3Ti_1.2Ta₁Cr_9.8Mo_0.4W_3.2	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.5}$ $\bar{C r}$ $_{2.2}$
CMSX-4	Ni_63.6Co_9.3Re₁Al_12.6Ti_1.3Ta_2.2Cr_7.6Mo_0.4W₂	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.6}$ $\bar{C r}$ $_{1.6}$
René N5	Ni_63.3Co_8.4Re_1.1Al_13.9Ta_2.3Cr_8.1Mo_1.2W_1.7	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.7}$ $\bar{C r}$ $_{1.8}$
René 142	Ni_60.7Co_12.2Re_0.9Al_13.8Ta_2.1Cr_7.8Mo_0.9W_1.6	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.5}$ $\bar{C r}$ $_{1.7}$
IN738LC	Ni_59.1Co_8.3Fe_0.2Al_7.6Ti_4.1Nb_0.6Ta_0.6Cr_17.5Mo_1.1W_0.9	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.2}$ $\bar{C r}$ $_{3.5}$
U700	Ni_49.6Co_17.4Fe₁Al_8.9Ti_4.1Cr₁₆Mo₃	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.3}$ $\bar{C r}$ $_{3.4}$
René 80	Ni_59.5Co_8.9Al_6.4Ti_6.1Cr_15.3Mo_2.5W_1.3	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.1}$ $\bar{C r}$ $_{3.3}$
IN738	Ni_60.2Co_8.2Al_7.2Ti₄Nb_0.6Ta_0.5Cr_17.5Mo₁W_0.8	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.2}$ $\bar{C r}$ $_{3.4}$
K418	Ni_68.7Fe₁Al_12.6Ti_0.8Nb_1.2Cr_13.2Mo_2.5	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.5}$ $\bar{C r}$ $_{2.7}$
CM247LC	Ni₆₇Co₉Al_12.4Ti_0.9Ta₁Cr_6.8Mo_0.3W_2.6	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{1.3}$ $\bar{C r}$ $_{1.5}$
IN939	Ni_48.2Co_17.9Al₄Ti_4.4Nb_0.6Cr_24.4W_0.5	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{0.6}$ $\bar{C r}$ $_{4.5}$
RR1000	Ni_52.6Co_17.8Al_5.5Ti_4.1Ta_0.6Cr_16.4Mo₃	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{0.7}$ $\bar{C r}$ $_{3.3}$
Waspaloy	Ni_56.5Co_13.3Al_2.7Ti_3.6Cr_21.3Mo_2.6	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{0.1}$ $\bar{C r}$ $_{4.1}$
René 41	Ni_61.4Co_10.8Al_3.1Ti_3.6Cr_20.5Mo_0.6	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{A l}$ $_{0.1}$ $\bar{C r}$ $_{3.5}$
Haynes 282	Ni_55.6Co_9.8Fe_1.6Al_3.2Ti_2.5Cr_22.2Mo_5.1	［Al‒ $\bar{N i}$ $_{12}$ ］ $\bar{C r}$ $_{4.9}$
IN718	Ni_52.3Fe_19.3Al_1.1Ti_1.1Nb_3.2Cr_21.2Mo_1.8	［（ $\bar{A l}$ $_{0.9}$ $\bar{C r}$ $_{0.1}$ ）‒ $\bar{N i}$ $_{12}$ ］ $\bar{C r}$ $_{3.8}$
IN625	Ni₆₄Fe_2.7Al_0.4Ti_0.3Nb_2.3Cr_24.8Mo_5.5	［（ $\bar{A l}$ $_{0.5}$ $\bar{C r}$ $_{0.5}$ ）‒ $\bar{N i}$ $_{12}$ ］ $\bar{C r}$ $_{5}$
Hastelloy-X	Ni_48.3Co_1.4Fe_19.3Al_0.5Cr_24.7Mo_5.5W_0.3	［（ $\bar{A l}$ $_{0.1}$ $\bar{C r}$ $_{0.9}$ ）‒ $\bar{N i}$ $_{12}$ ］ $\bar{C r}$ $_{4.4}$

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Shujing Shi, Zhuo Li, Chen Yang, Ziheng Zeng, Xu Cheng, Haibo Tang, Huaming Wang. Research Progress on Crack Control and Composition Design of γ′ Phase Strengthened Nickel‑Based Superalloys Suitable for Laser Additive Manufacturing (Invited)[J]. Chinese Journal of Lasers, 2024, 51(10): 1002302

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Paper Information

Category: Laser Additive Manufacturing

Received: Dec. 26, 2023

Accepted: Mar. 4, 2024

Published Online: Apr. 26, 2024

The Author Email: Li Zhuo (lizhuo@buaa.edu.cn)

DOI:10.3788/CJL231577

Topics

laser devices and laser physics

Lasers and Laser Optics

Laser physics

laser manufacturing

Instrumentation, Measurement and Metrology

Table 1. Effects of elements on the metallurgical performance of γ' phase strengthened nickel-based superalloys[16]

Table 1. Effects of elements on the metallurgical performance of γ' phase strengthened nickel-based superalloys[16]

Table 2. Composition and cluster formula analysis of nickel-based superalloys[44,82,84-86]

Table 2. Composition and cluster formula analysis of nickel-based superalloys[44,82,84-86]

Table 1. Effects of elements on the metallurgical performance of γ' phase strengthened nickel-based superalloys^[16]

Table 1. Effects of elements on the metallurgical performance of γ' phase strengthened nickel-based superalloys^[16]

Table 2. Composition and cluster formula analysis of nickel-based superalloys^{[44,82,84-86]}

Table 2. Composition and cluster formula analysis of nickel-based superalloys^{[44,82,84-86]}