On the interplay of internal voids, mechanical properties, and residual stresses in additively manufactured Haynes 282

Bryan Lim; Keita Nomoto; Amy J. Clarke; Sudarsanam Suresh Babu; Sophie Primig; Xiaozhou Liao; Andrew J. Breen; Simon P. Ringer

doi:10.1016/j.addma.2023.103749

On the interplay of internal voids, mechanical properties, and residual stresses in additively manufactured Haynes 282

Bryan Lim, Keita Nomoto, Amy J. Clarke, Sudarsanam Suresh Babu, Sophie Primig, Xiaozhou Liao, Andrew J. Breen, Simon P. Ringer

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

Abstract

Complex geometries and topology optimisations for weight and materials savings are leading drivers for the additive manufacturing of Ni-based superalloys through electron beam powder bed fusion (PBF-EB). However, there is a marked departure in these geometrically complex components with respect to the thermal signatures understood in commonly studied prismatic PBF-EB test coupons. This often results in unaccounted site-specific microstructure-property variations in complex PBF-EB builds. Here, the effects of topological changes, such as intentionally engineered internal voids, on the mechanical performance of an as-fabricated Haynes 282 monolith is revealed. The internal voids serve as representative physical models for changing thermal boundary conditions with build height. Complementary local nanoindentations, multi-scale microscopy, and residual stress measurements were used to understand the mechanisms behind geometry-structure-property relationships. The results highlight the effectiveness and influence of changing thermal conditions on the local mechanical property response of PBF-EB Haynes 282.

Original language	English
Article number	103749
Journal	Additive Manufacturing
Volume	75
DOIs	https://doi.org/10.1016/j.addma.2023.103749
State	Published - Aug 5 2023
Externally published	Yes

Funding

The authors acknowledge the facilities, the scientific, and technical assistance of the teams at Sydney Microscopy & Microanalysis (SMM) and the Sydney Manufacturing Hub (SMH), which are Core Research Facilities at the University of Sydney. SMM is the University of Sydney's (USYD) node of Microscopy Australia. Dr. Alec Day's (USYD and Steam Instruments Inc.) contribution to Fig. 1 is acknowledged. Helpful discussions with Dr. Richard Harwood (USYD) on the processing and analysis of NCT data for Fig. 2 is acknowledged. Dr. Ulf Garbe (ANSTO) is acknowledged for assistance in collecting raw NCT data used to generate Fig. 2. Dr. Mark Reid (ANSTO) is acknowledged for assistance in collecting raw neutron diffraction data used to generate Fig. 11 and Fig. 12. Prof. Anna Paradowska (USYD and ANSTO) is acknowledged for helpful discussions in the planning of the residual stress measurements. 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. Prof. Sophie Primig was supported by the UNSW Scientia Fellowship Scheme. Dr. Bryan Lim gratefully acknowledges the Australian Centre for Neutron Scattering (ACNS), under neutron beam instrument Grant no. 9637, for supporting the neutron diffraction residual strain measurements at ANSTO. The contributions of Profs. Amy J. 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 the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL) are acknowledged for the fabrication of the PBF-EB H282 builds. The research at ORNL 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 ORNL's additive manufacturing equipment at ORNL's 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. The facilities and technical assistance of the teams at the Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL) are acknowledged for the fabrication of the PBF-EB H282 builds. The research at ORNL 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 ORNL’s additive manufacturing equipment at ORNL’s 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 . This manuscript has been authored in part by UT-Battelle, LLC, under Contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The publisher acknowledges the US government license to provide public access under the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ). The contributions of Profs. Amy J. 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. 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 . Prof. Sophie Primig was supported by the UNSW Scientia Fellowship Scheme . Dr. Bryan Lim gratefully acknowledges the Australian Centre for Neutron Scattering ( ACNS ), under neutron beam instrument Grant no. 9637 , for supporting the neutron diffraction residual strain measurements at ANSTO.

Funders	Funder number
Steam Instruments Inc.
Sydney Manufacturing Hub
Office of Naval Research	N00014-18-1-2794
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725
Office of Energy Efficiency and Renewable Energy
Oak Ridge National Laboratory
U.S. Navy
University of New South Wales	9637
University of Sydney
Department of Industry, Innovation and Science, Australian Government

Keywords

Boundary conditions
Electron beam powder bed fusion
Nanoindentation
Neutron diffraction
Superalloy

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.addma.2023.103749

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title = "On the interplay of internal voids, mechanical properties, and residual stresses in additively manufactured Haynes 282",

abstract = "Complex geometries and topology optimisations for weight and materials savings are leading drivers for the additive manufacturing of Ni-based superalloys through electron beam powder bed fusion (PBF-EB). However, there is a marked departure in these geometrically complex components with respect to the thermal signatures understood in commonly studied prismatic PBF-EB test coupons. This often results in unaccounted site-specific microstructure-property variations in complex PBF-EB builds. Here, the effects of topological changes, such as intentionally engineered internal voids, on the mechanical performance of an as-fabricated Haynes 282 monolith is revealed. The internal voids serve as representative physical models for changing thermal boundary conditions with build height. Complementary local nanoindentations, multi-scale microscopy, and residual stress measurements were used to understand the mechanisms behind geometry-structure-property relationships. The results highlight the effectiveness and influence of changing thermal conditions on the local mechanical property response of PBF-EB Haynes 282.",

keywords = "Boundary conditions, Electron beam powder bed fusion, Nanoindentation, Neutron diffraction, Superalloy",

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N2 - Complex geometries and topology optimisations for weight and materials savings are leading drivers for the additive manufacturing of Ni-based superalloys through electron beam powder bed fusion (PBF-EB). However, there is a marked departure in these geometrically complex components with respect to the thermal signatures understood in commonly studied prismatic PBF-EB test coupons. This often results in unaccounted site-specific microstructure-property variations in complex PBF-EB builds. Here, the effects of topological changes, such as intentionally engineered internal voids, on the mechanical performance of an as-fabricated Haynes 282 monolith is revealed. The internal voids serve as representative physical models for changing thermal boundary conditions with build height. Complementary local nanoindentations, multi-scale microscopy, and residual stress measurements were used to understand the mechanisms behind geometry-structure-property relationships. The results highlight the effectiveness and influence of changing thermal conditions on the local mechanical property response of PBF-EB Haynes 282.

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On the interplay of internal voids, mechanical properties, and residual stresses in additively manufactured Haynes 282

Abstract

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Keywords

UN SDGs

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