A melt pool temperature model in laser powder bed fabricated CM247LC Ni superalloy to rationalize crack formation and microstructural inhomogeneities

Di Wang, Sheng Li, Guowei Deng, Yang Liu, Moataz M. Attallah

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Abstract

This study of the laser powder bed fusion (LPBF) of γ′-strengthened Ni superalloy CM247LC focuses on the development of a melt pool temperature model to predict crack density within the alloy. This study also analyzes spatter and elemental evaporation, which might cause defects and inhomogeneities, at different melt pool temperatures. The melt pool temperature model provides more accurate predictions than the widely used energy density model. Spatter particles were collected and characterized to study their sizes and chemical compositions, compared with the virgin powder, recycled powder, and as-built samples, to probe the impact of their entrapment into the melt pool. This study also investigated Al evaporation, revealing that its extent does not correlate with the laser energy density and is believed to be rather limited by comparing the chemistry of the virgin powder and the build. Last, the impact of LPBF process parameters on the formation of these inhomogeneities, and accordingly crack formation, was studied using finite element analysis by estimating the maximum melt pool temperature and correlating it with the formation of the microstructural inhomogeneities. The morphology of the various cracking modes was associated with the process parameters.

Original languageEnglish
Pages (from-to)5221-5234
Number of pages14
JournalMetallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Volume52
Issue number12
Early online date5 Oct 2021
DOIs
Publication statusPublished - Dec 2021

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Metals and Alloys

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