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Thompson Y, Zissel K, Förner A, Gonzalez-Gutierrez J, Kukla C, Neumeier S, Felfer P. Metal fused filament fabrication of the nickel-base superalloy IN 718. J Mater Sci 2022; 57:9541-9555. [PMID: 35663460 PMCID: PMC9151575 DOI: 10.1007/s10853-022-06937-y] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 09/16/2021] [Accepted: 01/16/2022] [Indexed: 06/15/2023]
Abstract
This study demonstrates metal fused filament fabrication (MF3) as an alternative additive and highly flexible manufacturing method for free-form fabrication of high-performance alloys. This novel processing, which is similar to Metal injection molding (MIM), enables a significant reduction in manufacturing costs for complex geometries, since expensive machining can be avoided. Utilizing existing equipment and reducing material expense, MF3 can pave the way for new and low-cost applications of IN 718, which were previously limited by high manufacturing costs. Iterative process optimization is used to find the most suitable MF3 process parameters. High relative density above 97% after pressureless sintering can be achieved if temperature profiles and atmospheres are well adjusted for thermal debinding and sintering. In this study, the influence of processing parameters on the resulting microstructure of MF3 IN 718 is investigated. Samples sintered in vacuum show coarse-grained microstructure with an area fraction of 0.36% NbC at grain boundaries. Morphology and composition of formed precipitates are analyzed using transmission electron microscopy and atom probe tomography. The γ/γ″/γ' phases' characteristics for IN 718 were identified. Conventional heat treatment is applied for further tailoring of mechanical properties like hardness, toughness and creep behavior. Fabricated samples achieve mechanical properties similar to MIM IN 718 presented in literature.
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Affiliation(s)
- Yvonne Thompson
- Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute I, Martensstraße 5, 91058 Erlangen, Germany
| | - Kai Zissel
- Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute I, Martensstraße 5, 91058 Erlangen, Germany
| | - Andreas Förner
- Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute I, Martensstraße 5, 91058 Erlangen, Germany
| | - Joamin Gonzalez-Gutierrez
- Department of Polymer Engineering and Science, Institute of Polymer Processing, Montanuniversitaet Leoben, Otto Gloeckel-Str. 2, 8700 Leoben, Austria
- Materials Research and Technology Department, Luxembourg Institute of Science and Technology, Functional Polymers Unit, 5 rue Bommel, 4940 Hautcharage, Luxembourg
| | - Christian Kukla
- Industrial Liaison Department, Montanuniversitaet Leoben, Peter Tunner Str. 27, 8700 Leoben, Austria
| | - Steffen Neumeier
- Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute I, Martensstraße 5, 91058 Erlangen, Germany
| | - Peter Felfer
- Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg, Institute I, Martensstraße 5, 91058 Erlangen, Germany
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Förner A, Giese S, Arnold C, Felfer P, Körner C, Neumeier S, Göken M. Nanoscaled eutectic NiAl-(Cr,Mo) composites with exceptional mechanical properties processed by electron beam melting. Sci Rep 2020; 10:15153. [PMID: 32939021 PMCID: PMC7495003 DOI: 10.1038/s41598-020-72093-5] [Citation(s) in RCA: 6] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/08/2020] [Accepted: 08/21/2020] [Indexed: 11/24/2022] Open
Abstract
Eutectic NiAl-(Cr,Mo) composites are promising high temperature materials due to their high melting point, excellent oxidation behavior and low density. To enhance the strength, hardness and fracture toughness, high cooling rates are beneficial to obtain a fine cellular-lamellar microstructure. This can be provided by the additive process of selective electron beam melting. The very high temperature gradient achieved in this process leads to the formation of the finest microstructure that has ever been reported for NiAl-(Cr,Mo) in-situ composites. A very high hardness and fracture toughening mechanisms were observed. This represents a feasibility study towards additive manufacturing of eutectic NiAl-(Cr,Mo) in-situ composites by selective electron beam melting.
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Affiliation(s)
- Andreas Förner
- Department of Materials Science and Engineering, Institute I, General Materials Properties, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Martensstraße 5, 91058, Erlangen, Germany.
| | - S Giese
- Department of Materials Science and Engineering, Institute I, General Materials Properties, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Martensstraße 5, 91058, Erlangen, Germany
| | - C Arnold
- Chair of Materials Science and Engineering for Metals, Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Erlangen, Germany
| | - P Felfer
- Department of Materials Science and Engineering, Institute I, General Materials Properties, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Martensstraße 5, 91058, Erlangen, Germany
| | - C Körner
- Chair of Materials Science and Engineering for Metals, Department of Materials Science and Engineering, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Erlangen, Germany
| | - S Neumeier
- Department of Materials Science and Engineering, Institute I, General Materials Properties, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Martensstraße 5, 91058, Erlangen, Germany
| | - M Göken
- Department of Materials Science and Engineering, Institute I, General Materials Properties, Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU), Martensstraße 5, 91058, Erlangen, Germany
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