Effect of Al on Microstructure and Mechanical Properties of ATI 718Plus by Laser Additive Manufacturing

doi:10.1007/s40195-024-01764-3

Abstract

Abstract:

To clarify the mechanism of the role of Al element in the additive manufacturing of Ni-based superalloys, ATI 718Plus alloys with varying Al contents (1, 3, and 5 wt%) were fabricated using the laser additive manufacturing and the effects of Al content on the microstructure and mechanical properties were systematically analyzed. The experimental and CALPHAD simulation results show that with the increase in Al addition, the freezing range of the alloys was lowered, but this has a paradoxical effect on the susceptibility of the alloy to hot-tearing and solid-state cracking. The addition of Al increased the γ′ and Laves phase volume fractions and suppressed the precipitation of the η phase. Simultaneously improving γ/γ′ lattice misfits effectively promoted the transformation of γ′ phase from spherical to cubic. The precipitation of NiAl phase in the 5 wt% Al-added alloy was determined, the formation mechanism of NiAl phase was analyzed, and the solidification sequence of the precipitated phase in the alloy was summarized. In addition, with the increase in Al addition, the microhardness of the alloy increased gradually, the tensile strength increased at first and then decreased, but the plasticity deteriorated seriously. The insights gained from this study offer valuable theoretical guidance for the strategic compositional design of additively manufactured Ni-based superalloys destined for deployment under extreme conditions.

Key words: Laser additive manufacturing, ATI 718Plus, Laves phase, Microstructure, Mechanical properties

Zhipeng Zhang, Jide Liu, Xinguang Wang, Zhaokuang Chu, Yizhou Zhou, Jianjun Wang, Jinguo Li. Effect of Al on Microstructure and Mechanical Properties of ATI 718Plus by Laser Additive Manufacturing[J]. Acta Metallurgica Sinica (English Letters), 2024, 37(11): 1891-1906.

Figures/Tables 20

Table 1 Chemical compositions of 718Plus alloy powder (wt%)

Alloy	Al	Ti	Nb	W + Mo + Cr + Co	Fe	C	Ni
1 wt% Al	1.65	0.8	5.6	30-33	9.9	0.024	Bal.
3 wt% Al	3.65	0.8	5.6	30-33	9.9	0.024	Bal.
5 wt% Al	5.65	0.8	5.6	30-33	9.9	0.024	Bal

Fig. 1 Surface morphology, cross-sectional morphology, and particle size distribution of 718Plus alloy powders with different Al additions: a, d, g 1 wt% Al; b, e, h 3 wt% Al; c, f, i 5 wt% Al

Table 2 Parameters for the LMD process

Laser power (W)	Scanning speed (mm/s)	Powder feeding rate (g/min)	Spot diameter (mm)	Z-axis lifting height (mm)	Overlap (%)
900	8	7	2	0.7	50

Fig. 2 As-deposited 718Plus alloy with different Al additions: a macroscopic morphology; b schematic diagram of microstructure and tensile sample

Fig. 3 OM images before and after corrosion of as-deposited 718Plus alloy with different Al additions: a and d 1 wt% Al; b and e 3 wt% Al; c and f 5 wt% Al

Fig. 4 a XRD patterns of as-deposited 718Plus alloy with different Al additions; b local magnification in a

Fig. 5 Laves phase of as-deposited 718Plus alloy with different Al additions: a 1 wt% Al; b 3 wt% Al; c 5 wt% Al; d variation trend of Laves phase volume fraction in different samples

Fig. 6 EPMA mapping of as-deposited 718Plus alloy with different Al additions: a 1 wt% Al; b 3 wt% Al; c 5 wt% Al

Fig. 7 Microstructures of as-deposited 718Plus alloy with different Al additions: a-c 1 wt% Al; d-f 3 wt% Al; g-i 5 wt% Al

Fig. 8 Microstructures of 1 wt% Al-added 718Plus alloy: a high-resolution TEM image of the surface between the Laves and η phase; b FFT image of the Laves phase; c FFT image of the phase interface between the Laves and η phase; d high-resolution TEM image of the surface between the γ and γ′ phase; e FFT image of the γ′ phase; f TEM bright image of the oxide and MC carbide; g TEM-EDS elemental maps of f

Fig. 9 Tensile properties of as-deposited 718Plus alloy with different Al additions: a Vickers microhardness; b engineering stress-strain curves; c compared with various types of as-deposited Inconel 718 alloy

Fig. 10 Fracture morphologies of as-deposited 718Plus alloy with different Al additions: a and d 1 wt% Al; b and e 3 wt% Al; c and f 5 wt% Al

Fig. 11 Scheil solidification curves of as-deposited 718Plus alloy with different Al additions: a 1 wt% Al; b 3 wt% Al; c 5 wt% Al

Fig. 12 Cooling curves of DSC of as-deposited 718Plus alloy with different Al additions

Fig. 13 CALPHAD analyses based on TCNI10 database: a phase diagrams of 1 wt% Al-added 718Plus alloy; b phase diagrams of 3 wt% Al-added 718Plus alloy, c phase diagrams of 5 wt% Al-added 718Plus alloy; d the interfacial energy between NiAl phase and the γ matrix; e normalized driving force between NiAl phase and the γ matrix; f the phase diagram of Ni-Al binary alloy

Fig. 14 Elemental segregation of as-deposited 718Plus alloy with different Al additions: a 1 wt% Al; b 3 wt% Al; c 5 wt% Al

Fig. 15 Profiles of diffraction peaks (111) fitting results and γ/γ′ lattice misfits of as-deposited 718Plus alloy with different Al additions: a 1 wt% Al; b 3 wt% Al; c 5 wt% Al; d γ/γ′ lattice misfits

Table 3 Lattice parameters of the γ and γ′ and the γ/γ′ lattice misfits of as-deposited 718Plus alloy with different Al additions

Sample	1 wt% Al	3 wt% Al	5 wt% Al
ɑ_γ_′ (nm)	0.19379	0.19394	0.19399
ɑ_γ (nm)	0.19368	0.19366	0.19357
δ (%)	0.05247	0.14079	0.21548

Fig. 16 Schematic diagram of microstructure evolution of as-deposited 718Plus alloy with different Al additions: a, d, g 1 wt% Al; b, e, h 3 wt% Al; c, f, i 5 wt% Al

Fig. 17 Longitudinal sections of fracture surfaces after tensile testing of 718Plus alloy in the as-deposited state with different Al additions: a and d 1 wt% Al; b and e 3 wt% Al; c and f 5 wt% Al

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