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Research Article

Microstructure and mechanical property of a nickel-based superalloy fabricated by laser powder-bed fusion using recycled powders

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  • Received: 4 June 2020Revised: 21 July 2020Accepted: 21 July 2020Available online: 24 July 2020
  • Evaluating the recyclability of powders in the additive manufacturing field has been a long-term challenge, and in this work, the microstructure and mechanical property of a nickel-based superalloy fabricated by laser powder-bed fusion (LPBF) using recycled powders were investigated. Re-melt surface, satellite, and deformed layer were found on the recycled powders combined with a high oxygen-containing surface layer. The increasing oxygen content led to the formation of high-density oxide inclusions, and the printing-induced cracks widely existed and mainly formed along the grain boundary in the as-built LPBF nickel-based superalloys using recycled powders. Changing the Si or Mn contents a little did not increase the hot cracking susceptibility of the printed parts, while the changed aspect ratio and surface damage of the recycled powders might contribute to the increasing density of cracks. Moreover, the configuration of cracks in the as-built parts led to the anisotropic mechanical properties, mainly resulting in an extremely low ductility vertical to the building direction, and the cracks mainly propagated along the cellular boundary due to the existence of a brittle precipitation phase.
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Microstructure and mechanical property of a nickel-based superalloy fabricated by laser powder-bed fusion using recycled powders

  • Corresponding author:

    Chao-fang Dong    E-mail: cfdong@ustb.edu.cn

  • 1. Beijing Advanced Innovation Center for Materials Genome Engineering, University of Science and Technology Beijing, Beijing 100083, China
  • 2. Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai 200437, China
  • 3. School of Materials Science and Engineering, Ocean University of China, Qingdao 266100, China

Abstract: Evaluating the recyclability of powders in the additive manufacturing field has been a long-term challenge, and in this work, the microstructure and mechanical property of a nickel-based superalloy fabricated by laser powder-bed fusion (LPBF) using recycled powders were investigated. Re-melt surface, satellite, and deformed layer were found on the recycled powders combined with a high oxygen-containing surface layer. The increasing oxygen content led to the formation of high-density oxide inclusions, and the printing-induced cracks widely existed and mainly formed along the grain boundary in the as-built LPBF nickel-based superalloys using recycled powders. Changing the Si or Mn contents a little did not increase the hot cracking susceptibility of the printed parts, while the changed aspect ratio and surface damage of the recycled powders might contribute to the increasing density of cracks. Moreover, the configuration of cracks in the as-built parts led to the anisotropic mechanical properties, mainly resulting in an extremely low ductility vertical to the building direction, and the cracks mainly propagated along the cellular boundary due to the existence of a brittle precipitation phase.

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