Formation and Evolution of Surface Morphology in Overhang Structure of IN718 Superalloy Fabricated by Laser Powder Bed Fusion

Controlling the overhang surface quality is still a formidable challenge in manufacturing the components with complex structures during laser powder bed fusion(LPBF).This study systematically uncovers the effects of the volume energy density(VED)and overhang angle on the evolution of surface morphology and corresponding surface roughness(Ra)of top and down-skin surfaces of IN718 superalloy samples.The results show that balling,Plateau-Rayleigh instability,open pore and humping caused by the material stacking are the main factors contributing to the apparent deterioration of top surface quality.When the VED is 80–100 J/mm^(3),the high down-skin surface roughness is attributed to the serious dross caused by recoil pressure and sinking of the melt pool.Using insufficient VED(15–50 J/mm^(3))can easily lead to poor metallurgical bonding and material spalling on the down-skin surface.In addition,overhang angle also significantly affects down-skin surface roughness due to the stair effect and the adhered unmelted powders.An improvement in the surface quality of down-skin surface is observed when the overhang angle increases.Based on the finding of this investigation,an optical VED(59.5 J/mm^(3))significantly improves the top and down-skin surface quality and porosity of overhang samples.This study provides an insight into synergy ascension of the top and down-skin surface quality in the overhang structure.

Effects of Thermally Assisted Warm Laser Shock Processing on the Microstructure and Fatigue Property of IN718 Superalloy

The effects of laser shock processing(LSP)and warm laser shock processing(WLSP)on the microstructure of surface hardening layer and high-cycle fatigue performance at room temperature and high temperature(600°C)of IN718 alloy were investigated.It has been revealed that the grain refined hardening layer with greater residual compression stresses,higher fraction of coincidence site lattice(CSL)boundaries and dislocation densities was formed in WLSP-treated alloy than in LSP-treated alloys.Moreover,microtwins includedγ″phase/high density dislocation complex was found in the surface of WLSP-treated alloy.These characters caused the significant enhancement of the medium value fatigue strength of WLSP-treated alloy at room temperature and elevated temperature.Apparently,the microtwins includedγ″phase/high density dislocation complex formed in the surface hardening layer of LSP-treated alloy has more complicated steric structure and more stable at elevated temperature thanγ″phase/low density dislocation complex formed in LSP-treated alloy,leading to the slow recovery process.Therefore,the surface hardening layer in the WLSP-treated alloy remained more ideal strengthening effect under high-cycle fatigue at elevated temperature than that in LSP-treated alloy.This resulted in the much longer fatigue crack initiation incubation and longer high-cycle life of WLSP-treated IN718 alloy under cycling load at 600℃.This discovery provides a new cognition of fatigue resistance by WLSP treatment of precipitation strengthening superalloy.

Constitutive Equation of Superalloy In718 in Hammer Forging Process

A constitutive equation reflecting the flow behavior of Superalloy In718 during the counter-blow hammer forging process was developed in terms of the relationship of flow stress and hot-deformation parameters,such as strain,strain rate,and deformation temperature.A new simplified approach for the complex multi-pass stress-strain curves has been attempted.The simulation curves calculated by constitutive equation are consistent with the experimental data.

CONSTITUTIVE RELATIONSHIP OF SUPERALLOY IN718

Isothermal constant speed compression tests of superalloy IN718 were conducted using a computer-controlled MTS machine at temperatures from 960 to 1040℃, with initial strain rates from 0.001 s￣(1) to 1.0 s￣(1) and engineering strain from 0.1 to 0. 7.The variations of flow stress with deformation temperature, initial strain rate and engineering strain were analyzed in the paper. It was found that there was an obvious power-law relationship between flow stress and initial strain rate, which showed the behavior of strain rate hardening of superalloy IN718 at elevated temperatures.The relationship between flow stress and temperature could be described by an inverse trigonometric function.And the turning point on the curve may be related to the behavior of δ phase at 1000℃. Meanwhile, it was found that there was a complicated relationship between flow stress and strain,which was indicative of the comprehensive effect of work hardening and dynamic softening on flow stress during hot deformation. From the results of these tests, a constitutive equation of superalloy IN718 was developed.

Processing and Microstructural Evolution of Superalloy Inconel 718 during Hot Tube Extrusion

The processing parameters of tube extrusion for superalloy Inconel 718 (IN 718), such as slug temperature, tools temperature, choice of lubricant, extrusion ratio and extrusion speed, were determined by experiment in this paper. An appropriate temperature range recommended for the slug is 1080-1120℃, and the temperature range recommended for the tools is 350-500℃. The microstructural evolution of superalloy IN 718 during tube extrusion was analyzed. With the increase of the deformation the cross crystal grains were slightly refined. While the vertical crystal grain is elongated evidently and the tensile strength increased along the axial rake. Glass lubricants have to be spread on the slug surface after being heated to 150-200℃, vegetable oil or animal oil can be used as the lubricant on the surface of the tools to reduce the extrusion force remarkably.

Improvement on Hot Workability of γ-TiAl Base Alloy

A constitutive equation reflecting the flow behavior of Superalloy In718 during the counter blow hammer forging process was developed in terms of the relationship of flow stress and hot deformation parameters, such as strain, strain rate, and deformation temperature. A new simplified approach for the complex multi pass stress strain curves has been attempted. The simulation curves calculated by constitutive equation are consistent with the experimental data.

Comparison of the very high cycle fatigue behaviors of INCONEL 718 with different loading frequencies

In order to clarify the differences of very high cycle fatigue(VHCF) behavior of nickel based superalloy IN718 with different loading frequencies,stress-controlled fatigue tests were carried out by using ultrasonic testing method(20 KHz) and rotary bending testing method(52.5 Hz),both at room temperatures,to establish stress versus cycles to failure(S-N) relationships.Results disclosed that cycles to failure at a given stress level increased with an increase of the applied frequency,i.e.,the higher frequency produced an upper shift of the S-N curves.Fractographic analysis suggested that crack initiation and propagation behaviors had large differences:cracks in low-frequency tests preferentially initiated from multiple sources on the specimen surface,while in high-frequency tests,cracks mostly originated from a unique source of subsurface inclusions.Subsequently,frequency-involved modeling was proposed,based on the damage accumulation theory,which could well illustrate qualitatively those comparisons due to different loading frequencies.