Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ′ CoNi-Base Superalloy Variants

Evan B. Raeker; Kira M. Pusch; Kaitlyn M. Mullin; James D. Lamb; Ning Zhou; Stéphane A.J. Forsik; Austin D. Dicus; Michael M. Kirka; Tresa M. Pollock

doi:10.1007/978-3-031-63937-1_88

Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ^′ CoNi-Base Superalloy Variants

Evan B. Raeker
, Kira M. Pusch
, Kaitlyn M. Mullin
, James D. Lamb
, Ning Zhou
, Stéphane A.J. Forsik
, Austin D. Dicus
, Michael M. Kirka
, Tresa M. Pollock

Deposition Science and Technology

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

3 Scopus citations

Abstract

Additive manufacturingAdditive manufacturing enables the fabrication of complex part geometries, and is attractive for advanced aerospace components. Laser powder bed fusion (LPBF)Laser Powder Bed Fusion (LPBF), specifically, is being assessed for manufacturing structural components of gas-turbine engines made from high-γ^′ volume fraction superalloys. However, the formation of crack defects during LPBFLaser Powder Bed Fusion (LPBF) of nearly all superalloys within this class has undercut their mechanical performance greatly. This study builds on prior work examining the cracking susceptibility of high-γ^′ volume fraction superalloys during LPBF by simplifying the LPBF process down to single track laser meltingLaser melting scans. The CoNi-base alloy GammaPrint-700 is utilized in this study, as the cracking resistance of the alloy can be controlled through the boronBoron content. A means of improving the cracking resistance of the alloy through homogenization treatments prior to laser meltingLaser melting was identified. Characterization of the single tracks reveals a possible mechanism of crack initiationCrack initiation via liquation cracking of grain boundariesGrain boundary in the substrate material, and propagation via solidification crackingSolidification cracking along grain boundariesGrain boundary in the melt pool. Additionally, a protocol for assessing the cracking resistance while developing new high-γ^′ volume fraction superalloys for additive manufacturingAdditive manufacturing is discussed.

Original language	English
Title of host publication	Superalloys 2024 - Proceedings of the 15th International Symposium on Superalloys
Editors	Jonathan Cormier, Ian Edmonds, Stephane Forsik, Paraskevas Kontis, Corey O’Connell, Timothy Smith, Akane Suzuki, Sammy Tin, Jian Zhang
Publisher	Springer Science and Business Media Deutschland GmbH
Pages	948-957
Number of pages	10
ISBN (Print)	9783031639364
DOIs	https://doi.org/10.1007/978-3-031-63937-1_88
State	Published - 2024
Event	15th International Symposium on Superalloys, ISS 2024 - Pennsylvania, United States Duration: Sep 8 2024 → Sep 12 2024

Publication series

Name	Minerals, Metals and Materials Series
ISSN (Print)	2367-1181
ISSN (Electronic)	2367-1696

Conference

Conference	15th International Symposium on Superalloys, ISS 2024
Country/Territory	United States
City	Pennsylvania
Period	09/8/24 → 09/12/24

Funding

This research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy (EERE), Advanced Materials & Manufacturing Technologies Office (AMMTO), under Contract DE-AC05-00OR22725 with UT-Battelle LLC. The research reported here made use of shared facilities of the National Science Foundation (NSF) Materials Research Science and Engineering Center (MRSEC) at UC Santa Barbara, NSF DMR-2308708. The UC Santa Barbara MRSEC is a member of the Materials Research Facilities Network (www.mrfn.org).

Keywords

Additive manufacturing
Laser melting
Solidification cracking
γ-strengthened superalloys

Access to Document

10.1007/978-3-031-63937-1_88

Cite this

Raeker, E. B., Pusch, K. M., Mullin, K. M., Lamb, J. D., Zhou, N., Forsik, S. A. J., Dicus, A. D., Kirka, M. M., & Pollock, T. M. (2024). Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ^′ CoNi-Base Superalloy Variants. In J. Cormier, I. Edmonds, S. Forsik, P. Kontis, C. O’Connell, T. Smith, A. Suzuki, S. Tin, & J. Zhang (Eds.), Superalloys 2024 - Proceedings of the 15th International Symposium on Superalloys (pp. 948-957). (Minerals, Metals and Materials Series). Springer Science and Business Media Deutschland GmbH. https://doi.org/10.1007/978-3-031-63937-1_88

Raeker, Evan B. ; Pusch, Kira M. ; Mullin, Kaitlyn M. et al. / Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ^′ CoNi-Base Superalloy Variants. Superalloys 2024 - Proceedings of the 15th International Symposium on Superalloys. editor / Jonathan Cormier ; Ian Edmonds ; Stephane Forsik ; Paraskevas Kontis ; Corey O’Connell ; Timothy Smith ; Akane Suzuki ; Sammy Tin ; Jian Zhang. Springer Science and Business Media Deutschland GmbH, 2024. pp. 948-957 (Minerals, Metals and Materials Series).

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title = "Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ′ CoNi-Base Superalloy Variants",

abstract = "Additive manufacturingAdditive manufacturing enables the fabrication of complex part geometries, and is attractive for advanced aerospace components. Laser powder bed fusion (LPBF)Laser Powder Bed Fusion (LPBF), specifically, is being assessed for manufacturing structural components of gas-turbine engines made from high-γ′ volume fraction superalloys. However, the formation of crack defects during LPBFLaser Powder Bed Fusion (LPBF) of nearly all superalloys within this class has undercut their mechanical performance greatly. This study builds on prior work examining the cracking susceptibility of high-γ′ volume fraction superalloys during LPBF by simplifying the LPBF process down to single track laser meltingLaser melting scans. The CoNi-base alloy GammaPrint-700 is utilized in this study, as the cracking resistance of the alloy can be controlled through the boronBoron content. A means of improving the cracking resistance of the alloy through homogenization treatments prior to laser meltingLaser melting was identified. Characterization of the single tracks reveals a possible mechanism of crack initiationCrack initiation via liquation cracking of grain boundariesGrain boundary in the substrate material, and propagation via solidification crackingSolidification cracking along grain boundariesGrain boundary in the melt pool. Additionally, a protocol for assessing the cracking resistance while developing new high-γ′ volume fraction superalloys for additive manufacturingAdditive manufacturing is discussed.",

keywords = "Additive manufacturing, Laser melting, Solidification cracking, γ-strengthened superalloys",

author = "Raeker, \{Evan B.\} and Pusch, \{Kira M.\} and Mullin, \{Kaitlyn M.\} and Lamb, \{James D.\} and Ning Zhou and Forsik, \{St{\'e}phane A.J.\} and Dicus, \{Austin D.\} and Kirka, \{Michael M.\} and Pollock, \{Tresa M.\}",

note = "Publisher Copyright: {\textcopyright} The Minerals, Metals \& Materials Society 2024.; 15th International Symposium on Superalloys, ISS 2024 ; Conference date: 08-09-2024 Through 12-09-2024",

year = "2024",

doi = "10.1007/978-3-031-63937-1\_88",

language = "English",

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series = "Minerals, Metals and Materials Series",

publisher = "Springer Science and Business Media Deutschland GmbH",

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Raeker, EB, Pusch, KM, Mullin, KM, Lamb, JD, Zhou, N, Forsik, SAJ, Dicus, AD, Kirka, MM & Pollock, TM 2024, Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ^′ CoNi-Base Superalloy Variants. in J Cormier, I Edmonds, S Forsik, P Kontis, C O’Connell, T Smith, A Suzuki, S Tin & J Zhang (eds), Superalloys 2024 - Proceedings of the 15th International Symposium on Superalloys. Minerals, Metals and Materials Series, Springer Science and Business Media Deutschland GmbH, pp. 948-957, 15th International Symposium on Superalloys, ISS 2024, Pennsylvania, United States, 09/8/24. https://doi.org/10.1007/978-3-031-63937-1_88

Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ^′ CoNi-Base Superalloy Variants. / Raeker, Evan B.; Pusch, Kira M.; Mullin, Kaitlyn M. et al.
Superalloys 2024 - Proceedings of the 15th International Symposium on Superalloys. ed. / Jonathan Cormier; Ian Edmonds; Stephane Forsik; Paraskevas Kontis; Corey O’Connell; Timothy Smith; Akane Suzuki; Sammy Tin; Jian Zhang. Springer Science and Business Media Deutschland GmbH, 2024. p. 948-957 (Minerals, Metals and Materials Series).

Research output: Chapter in Book/Report/Conference proceeding › Conference contribution › peer-review

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AU - Raeker, Evan B.

AU - Pusch, Kira M.

AU - Mullin, Kaitlyn M.

AU - Lamb, James D.

AU - Zhou, Ning

AU - Forsik, Stéphane A.J.

AU - Dicus, Austin D.

AU - Kirka, Michael M.

AU - Pollock, Tresa M.

N1 - Publisher Copyright: © The Minerals, Metals & Materials Society 2024.

PY - 2024

Y1 - 2024

N2 - Additive manufacturingAdditive manufacturing enables the fabrication of complex part geometries, and is attractive for advanced aerospace components. Laser powder bed fusion (LPBF)Laser Powder Bed Fusion (LPBF), specifically, is being assessed for manufacturing structural components of gas-turbine engines made from high-γ′ volume fraction superalloys. However, the formation of crack defects during LPBFLaser Powder Bed Fusion (LPBF) of nearly all superalloys within this class has undercut their mechanical performance greatly. This study builds on prior work examining the cracking susceptibility of high-γ′ volume fraction superalloys during LPBF by simplifying the LPBF process down to single track laser meltingLaser melting scans. The CoNi-base alloy GammaPrint-700 is utilized in this study, as the cracking resistance of the alloy can be controlled through the boronBoron content. A means of improving the cracking resistance of the alloy through homogenization treatments prior to laser meltingLaser melting was identified. Characterization of the single tracks reveals a possible mechanism of crack initiationCrack initiation via liquation cracking of grain boundariesGrain boundary in the substrate material, and propagation via solidification crackingSolidification cracking along grain boundariesGrain boundary in the melt pool. Additionally, a protocol for assessing the cracking resistance while developing new high-γ′ volume fraction superalloys for additive manufacturingAdditive manufacturing is discussed.

AB - Additive manufacturingAdditive manufacturing enables the fabrication of complex part geometries, and is attractive for advanced aerospace components. Laser powder bed fusion (LPBF)Laser Powder Bed Fusion (LPBF), specifically, is being assessed for manufacturing structural components of gas-turbine engines made from high-γ′ volume fraction superalloys. However, the formation of crack defects during LPBFLaser Powder Bed Fusion (LPBF) of nearly all superalloys within this class has undercut their mechanical performance greatly. This study builds on prior work examining the cracking susceptibility of high-γ′ volume fraction superalloys during LPBF by simplifying the LPBF process down to single track laser meltingLaser melting scans. The CoNi-base alloy GammaPrint-700 is utilized in this study, as the cracking resistance of the alloy can be controlled through the boronBoron content. A means of improving the cracking resistance of the alloy through homogenization treatments prior to laser meltingLaser melting was identified. Characterization of the single tracks reveals a possible mechanism of crack initiationCrack initiation via liquation cracking of grain boundariesGrain boundary in the substrate material, and propagation via solidification crackingSolidification cracking along grain boundariesGrain boundary in the melt pool. Additionally, a protocol for assessing the cracking resistance while developing new high-γ′ volume fraction superalloys for additive manufacturingAdditive manufacturing is discussed.

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KW - Laser melting

KW - Solidification cracking

KW - γ-strengthened superalloys

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Raeker EB, Pusch KM, Mullin KM, Lamb JD, Zhou N, Forsik SAJ et al. Solidification and Crack Defect Formation on the Single Melt Track Scale for High γ^′ CoNi-Base Superalloy Variants. In Cormier J, Edmonds I, Forsik S, Kontis P, O’Connell C, Smith T, Suzuki A, Tin S, Zhang J, editors, Superalloys 2024 - Proceedings of the 15th International Symposium on Superalloys. Springer Science and Business Media Deutschland GmbH. 2024. p. 948-957. (Minerals, Metals and Materials Series). doi: 10.1007/978-3-031-63937-1_88