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

De-cheng Kong; Chao-fang Dong; Xiao-qing Ni; Liang Zhang; Rui-xue Li; Xing He; Cheng Man; Xiao-gang Li

doi:10.1007/s12613-020-2147-4

Volume 28 Issue 2

Feb. 2021

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Article Navigation > International Journal of Minerals, Metallurgy and Materials > 2021 > 28(2): 266-278

De-cheng Kong, Chao-fang Dong, Xiao-qing Ni, Liang Zhang, Rui-xue Li, Xing He, Cheng Man, and Xiao-gang Li, Microstructure and mechanical properties of nickel-based superalloy fabricated by laser powder-bed fusion using recycled powders, Int. J. Miner. Metall. Mater., 28(2021), No. 2, pp. 266-278. https://doi.org/10.1007/s12613-020-2147-4

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De-cheng Kong, Chao-fang Dong, Xiao-qing Ni, Liang Zhang, Rui-xue Li, Xing He, Cheng Man, and Xiao-gang Li, Microstructure and mechanical properties of nickel-based superalloy fabricated by laser powder-bed fusion using recycled powders, Int. J. Miner. Metall. Mater., 28(2021), No. 2, pp. 266-278. https://doi.org/10.1007/s12613-020-2147-4

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Research Article

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

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Corresponding author:
Chao-fang Dong E-mail: cfdong@ustb.edu.cn
Received: 20 June 2020; Revised: 21 July 2020; Accepted: 21 July 2020; Available online: 24 July 2020

Abstract

Abstract

Evaluating the recyclability of powders in additive manufacturing has been a long-term challenge. In this study, the microstructure and mechanical properties of a nickel-based superalloy fabricated by laser powder-bed fusion (LPBF) using recycled powders were investigated. Re-melted powder surfaces, satellite particles, and deformed powders were found in the recycled powders, combined with a high-oxygen-content surface layer. The increasing oxygen content led to the formation of high-density oxide inclusions; moreover, printing-induced cracks widely occurred and mainly formed along the grain boundaries in the as-built LPBF nickel-based superalloys fabricated using recycled powders. A little change in the Si or Mn content did not increase the hot cracking susceptibility (HCS) of the printed parts. The changing aspect ratio and the surface damage of the recycled powders might contribute to increasing the crack density. Moreover, the configuration of cracks in the as-built parts led to anisotropic mechanical properties, mainly resulting in extremely low ductility vertical to the building direction, and the cracks mainly propagated along the cellular boundary owing to the existence of a brittle precipitation phase.
- laser powder-bed fusion;
- recycled powder;
- cracking;
- anisotropy;
- nickel-based superalloy

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