Asymmetric Cracking in Mar-M247 Alloy Builds During Electron Beam Powder Bed Fusion Additive Manufacturing

Y. S. Lee; M. M. Kirka; S. Kim; N. Sridharan; A. Okello; R. R. Dehoff; S. S. Babu

doi:10.1007/s11661-018-4788-8

Asymmetric Cracking in Mar-M247 Alloy Builds During Electron Beam Powder Bed Fusion Additive Manufacturing

Y. S. Lee, M. M. Kirka, S. Kim, N. Sridharan, A. Okello, R. R. Dehoff, S. S. Babu

Research output: Contribution to journal › Article › peer-review

52 Scopus citations

Abstract

In the electron beam powder bed fusion (EB-PBF) process, a substantial number of high-gamma prime Ni-based superalloys are considered as non-printable due to a high propensity to form cracks. In this research, we focused on computational modeling framework to predict solidification-related cracking phenomena in EB-PBF processes. The cracking analysis was performed on cylindrical overhang structures where the cracks are observed only on one side of the part. Comprehensive microstructural characterization correlated the cracking tendency to low-melting point liquid-film formation along columnar grain boundaries with high misorientation angles due to partitioning of alloying elements. Uncoupled numerical thermal and mechanical models were used to rationalize the relationship between process parameters, build geometry, and cracking. The simulations showed asymmetric temperature distributions and associated asymmetric tensile thermal stresses over a cross section due to differences in section modulus and periodic changes in beam scanning directions. The results provide a potential pathway based on spatially varying beam scanning strategies to reduce the cracking tendency during additive manufacturing of complex geometries on the overhang structure in high-gamma prime nickel-based superalloys.

Original language	English
Pages (from-to)	5065-5079
Number of pages	15
Journal	Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Volume	49
Issue number	10
DOIs	https://doi.org/10.1007/s11661-018-4788-8
State	Published - Oct 1 2018

Funding

The research 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. The authors thank Dr. Alex Plotkowski of ORNL for constructive criticism. Notice of Copyright. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). Manuscript submitted February 7, 2018. Notice of Copyright. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). Manuscript submitted February 7, 2018. Article published online July 5, 2018

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title = "Asymmetric Cracking in Mar-M247 Alloy Builds During Electron Beam Powder Bed Fusion Additive Manufacturing",

abstract = "In the electron beam powder bed fusion (EB-PBF) process, a substantial number of high-gamma prime Ni-based superalloys are considered as non-printable due to a high propensity to form cracks. In this research, we focused on computational modeling framework to predict solidification-related cracking phenomena in EB-PBF processes. The cracking analysis was performed on cylindrical overhang structures where the cracks are observed only on one side of the part. Comprehensive microstructural characterization correlated the cracking tendency to low-melting point liquid-film formation along columnar grain boundaries with high misorientation angles due to partitioning of alloying elements. Uncoupled numerical thermal and mechanical models were used to rationalize the relationship between process parameters, build geometry, and cracking. The simulations showed asymmetric temperature distributions and associated asymmetric tensile thermal stresses over a cross section due to differences in section modulus and periodic changes in beam scanning directions. The results provide a potential pathway based on spatially varying beam scanning strategies to reduce the cracking tendency during additive manufacturing of complex geometries on the overhang structure in high-gamma prime nickel-based superalloys.",

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AU - Sridharan, N.

AU - Okello, A.

AU - Dehoff, R. R.

AU - Babu, S. S.

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N2 - In the electron beam powder bed fusion (EB-PBF) process, a substantial number of high-gamma prime Ni-based superalloys are considered as non-printable due to a high propensity to form cracks. In this research, we focused on computational modeling framework to predict solidification-related cracking phenomena in EB-PBF processes. The cracking analysis was performed on cylindrical overhang structures where the cracks are observed only on one side of the part. Comprehensive microstructural characterization correlated the cracking tendency to low-melting point liquid-film formation along columnar grain boundaries with high misorientation angles due to partitioning of alloying elements. Uncoupled numerical thermal and mechanical models were used to rationalize the relationship between process parameters, build geometry, and cracking. The simulations showed asymmetric temperature distributions and associated asymmetric tensile thermal stresses over a cross section due to differences in section modulus and periodic changes in beam scanning directions. The results provide a potential pathway based on spatially varying beam scanning strategies to reduce the cracking tendency during additive manufacturing of complex geometries on the overhang structure in high-gamma prime nickel-based superalloys.

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Asymmetric Cracking in Mar-M247 Alloy Builds During Electron Beam Powder Bed Fusion Additive Manufacturing

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