Abstract
Magnitude and distribution of residual stresses in additively manufactured Ni-based superalloys may impact the mechanical performance of as-fabricated parts. Though electron beam powder bed fusion (E-PBF) can produce components with minimal defects and residual stresses compared to laser powder bed fusion and directed energy deposition, variations of them may occur within the complex geometry of a component, due to inherent variations of thermal signatures and the evolution of section modulus along the build direction. This work reveals the residual stress distribution, characterised from neutron diffraction, of an as-fabricated Haynes 282 monolith containing internal cube voids and thin wall struts of varying thicknesses. Complementary local hardness measurements and multi-scale microscopy were used to investigate the geometry-structure-property relationships. Observed variations in hardness were attributed to a combination of type I macro-scale residual stresses and variations in bimodal γ′ precipitation behaviour. The results highlight the influence of residual stresses and microstructure on the mechanical properties of E-PBF Haynes 282.
| Original language | English |
|---|---|
| Article number | 103120 |
| Journal | Additive Manufacturing |
| Volume | 59 |
| DOIs | |
| State | Published - Nov 2022 |
| Externally published | Yes |
Funding
This research was sponsored by the Department of Industry, Innovation and Science under the auspices of the AUSMURI program which is a part of the Commonwealth’s Next Generation Technologies Fund. A/Prof. Sophie Primig is supported by the UNSW Scientia Fellowship scheme. Asst. Prof. Zibin Chen is supported by the Research Office of The Hong Kong Polytechnic University (Project code: P0039966 & P0039581 ). The facilities and technical assistance of the teams at Oak-Ridge National lab are acknowledged for the fabrication of the E-PBF Haynes 282 builds. The research at Oak-Ridge National Laboratory was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Access to the Oak Ridge National Laboratory’s (ORNL) additive manufacturing equipment at ORNL’s Manufacturing Demonstration Facility (MDF) was facilitated by US Department of Energy’s Strategic Partnership Projects (SPP) mechanism. More information can be found at https://science.energy.gov/lp/strategic-partnership-projects . Mr. Alec Saville gratefully acknowledges the National Science Foundation Graduate Research Fellowship, USA, under Grant No. 2019260337 for supporting the analyses related to Fig. 4 . Neutron diffraction measurements to generate Fig. 4 were supported by the Los Alamos Neutron Science Center (LANSCE), a NNSA User Facility operated for the US Department of Energy (DOE) by Los Alamos National Laboratory (LANL). LANL is operated by Triad National Security, LLC, for the National Nuclear Security Administration, USA, of US DOE (Contract No. 89233218CNA000001 ). The authors acknowledg the facilities, the scientific, and technical assistance of the teams at Sydney Microscopy & Microanalysis (SMM) and the Sydney Manufacturing Hub, which are Core Research Facilities at the University of Sydney. SMM is the University of Sydney's node of Microscopy Australia. Mr. James Dingle's (University of Sydney) contribution to Figs. 2 and 12 are acknowledged. This research was sponsored by the Department of Industry, Innovation and Science under the auspices of the AUSMURI program which is a part of the Commonwealth's Next Generation Technologies Fund. A/Prof. Sophie Primig is supported by the UNSW Scientia Fellowship scheme. Asst. Prof. Zibin Chen is supported by the Research Office of The Hong Kong Polytechnic University (Project code: P0039966 & P0039581). The contributions of Profs. Amy Clarke and Sudarsanam Suresh Babu were funded by the Department of the Navy, Office of Naval Research under ONR award number N00014-18-1-2794. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the Office of Naval Research. The facilities and technical assistance of the teams at Oak-Ridge National lab are acknowledged for the fabrication of the E-PBF Haynes 282 builds. The research at Oak-Ridge National Laboratory was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office under contract DE-AC05-00OR22725 with UT-Battelle, LLC. Access to the Oak Ridge National Laboratory's (ORNL) additive manufacturing equipment at ORNL's Manufacturing Demonstration Facility (MDF) was facilitated by US Department of Energy's Strategic Partnership Projects (SPP) mechanism. More information can be found at https://science.energy.gov/lp/strategic-partnership-projects. Mr. Alec Saville gratefully acknowledges the National Science Foundation Graduate Research Fellowship, USA, under Grant No. 2019260337 for supporting the analyses related to Fig. 4. Neutron diffraction measurements to generate Fig. 4 were supported by the Los Alamos Neutron Science Center (LANSCE), a NNSA User Facility operated for the US Department of Energy (DOE) by Los Alamos National Laboratory (LANL). LANL is operated by Triad National Security, LLC, for the National Nuclear Security Administration, USA, of US DOE (Contract No. 89233218CNA000001). The contributions of Profs. Amy Clarke and Sudarsanam Suresh Babu were funded by the Department of the Navy, Office of Naval Research under ONR award number N00014-18-1-2794 . Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the Office of Naval Research.
| Funders | Funder number |
|---|---|
| Los Alamos Neutron Science Center | |
| Research Office of The Hong Kong Polytechnic University | P0039581, P0039966 |
| National Science Foundation | 2019260337 |
| Office of Naval Research | N00014-18-1-2794 |
| U.S. Department of Energy | 89233218CNA000001 |
| Advanced Manufacturing Office | DE-AC05-00OR22725 |
| Office of Energy Efficiency and Renewable Energy | |
| National Nuclear Security Administration | |
| Oak Ridge National Laboratory | |
| Los Alamos National Laboratory | |
| U.S. Navy | |
| University of New South Wales | |
| University of Sydney | |
| Department of Industry, Innovation and Science, Australian Government |
Keywords
- Electron beam powder bed fusion
- Hardness
- Neutron diffraction
- Residual stress
- Superalloy
