Top

Journal of Materials Engineering and Performance

Published in:

26-08-2021

Effect of Scan Speed and Laser Power on the Nature of Defects, Microstructures and Microhardness of 3D-Printed Inconel 718 Alloy

Authors: Pravin Kumar, P. Chakravarthy, Sushant K. Manwatkar, S. V. S. Narayana Murty

Published in: Journal of Materials Engineering and Performance | Issue 9/2021

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Inconel 718 samples were printed with varying scan speed and laser power with volume energy density (VED) in the range of 52 J/mm³ to 75 J/mm³. Samples were then subjected to solution treatment and aging as per standards. Further, samples were characterized for their microstructure and metallurgical defects using optical microscopy (OM) and scanning electron microscopy. OM revealed that columnar grains had grown epitaxially in the build direction and grain size varies from bottom to top. Microscopic analysis on the XY plane (laser focusing plane) and the XZ plane (the plane in build direction) had revealed the presence of defects like metallurgical pores, interlayer cracks, open pores, lack of fusion, balling defects and their different morphologies. The process parameters such as scan speed, laser power and VED have influenced the porosity % and pore density and their distribution in the printed material. The microstructures also revealed the presence of oxides of Cr, Nb, Ti, Al and Fe which were identified near the interlayer cracks, large open pores and clusters of pores. Microhardness measurements of the printed samples were higher than the wrought Inconel 718 by 15-18%, both in the solution treated and aged conditions. The microhardness survey along the XY and XZ planes yielded different values even after double aging heat treatment. Average microhardness on the XZ plane was 15-20% more than that on the XY plane in each sample pertaining to the difference in grain morphology on the two planes. This difference in the microhardness values was less for the sample of high VED. The results suggest that VED in the range of 65 J/mm³ to 70 J/mm³ with scan speed and laser power between 860 mm/s to 970 mm/s and 260 W to 300 W, respectively, result in samples with tolerable microscopic defects.

previous article Stress Corrosion Cracking Susceptibility of Additively Manufactured Aluminum Alloy 7050 Produced by Selective Laser Melting in Chloride Environments

next article Correction to: Characterization and Optimization of Process Parameters for Directed Energy Deposition Powder-Fed Laser System

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

R.J. Hebert, Viewpoint: Metallurgical Aspects of Powder Bed Metal Additive Manufacturing, J. Mater. Sci., 2016, 51(3), p 1165–1175. https://doi.org/10.1007/s10853-015-9479-xCrossRef

D. Gu, Laser additive manufacturing of high-performance materials, Laser Addit. Manuf. High-Performance Mater., no. Lm, pp. 1–311, 2015, doi: https://doi.org/10.1007/978-3-662-46089-4

W.J. Sames, F.A. List, S. Pannala, R.R. Dehoff and S.S. Babu, The Metallurgy and Processing Science of Metal Additive Manufacturing, Int. Mater. Rev., 2016, 61(5), p 315–360. https://doi.org/10.1080/09506608.2015.1116649CrossRef

A. Mostafa, I.P. Rubio, V. Brailovski, M. Jahazi and M. Medraj, Structure, Texture and Phases in 3D Printed IN718 Alloy Subjected to Homogenization and HIP Treatments, Metals (Basel), 2017, 7(6), p 1–23. https://doi.org/10.3390/met7060196CrossRef

R. C. Benn and R. P. Salva, “Additively manufactured INCONEL® alloy 718,” 7th Int. Symp. Superalloy 718 Deriv. 2010, vol. 1, pp. 455–469, 2010, doi: https://doi.org/10.1002/9781118495223.ch35

J.J. Beaman et al., “Direct SLS Fabrication of Metals and Ceramics”, in Solid Freeform Fabrication: A New Direction in Manufacturing, Springer, US, 1997, p 245–278CrossRef

T. Trosch, J. Strößner, R. Völkl and U. Glatzel, Microstructure and Mechanical Properties of Selective Laser Melted Inconel 718 Compared to Forging and Casting, Mater. Lett., 2016, 164, p 428–431. https://doi.org/10.1016/j.matlet.2015.10.136CrossRef

M. Turker, D. Godlinski and F. Petzoldt, Effect of Production Parameters on the Properties of IN 718 Superalloy by Three-Dimensional Printing, Mater. Charact., 2008, 59(12), p 1728–1735. https://doi.org/10.1016/j.matchar.2008.03.017CrossRef

Q. Jia and D. Gu, Selective Laser Melting Additive Manufacturing of Inconel 718 Superalloy Parts: Densification, Microstructure and Properties, J. Alloys Compd., 2014, 585, p 713–721. https://doi.org/10.1016/j.jallcom.2013.09.171CrossRef

10.

M.H. Farshidianfar, A. Khajepour and A.P. Gerlich, Effect of Real-Time Cooling Rate on Microstructure in Laser Additive Manufacturing, J. Mater. Process. Technol., 2016, 231, p 468–478. https://doi.org/10.1016/j.jmatprotec.2016.01.017CrossRef

11.

Z. Wang, K. Guan, M. Gao, X. Li, X. Chen and X. Zeng, The Microstructure and Mechanical Properties of Deposited-IN718 by Selective Laser Melting, J. Alloys Compd., 2012, 513, p 518–523. https://doi.org/10.1016/j.jallcom.2011.10.107CrossRef

12.

K. Moussaoui, W. Rubio, M. Mousseigne, T. Sultan and F. Rezai, Effects of Selective Laser Melting Additive Manufacturing Parameters of Inconel 718 on Porosity, Microstructure and Mechanical Properties, Mater. Sci. Eng. A, 2018, 735, p 182–190. https://doi.org/10.1016/j.msea.2018.08.037CrossRef

13.

U. Scipioni Bertoli, A.J. Wolfer, M.J. Matthews, J.P.R. Delplanque and J.M. Schoenung, On the Limitations of Volumetric Energy Density as a Design Parameter for Selective Laser Melting, Mater. Des., 2017, 113, p 331–340. https://doi.org/10.1016/j.matdes.2016.10.037CrossRef

14.

A. Simchi and H. Pohl, Effects of Laser Sintering Processing Parameters on the Microstructure and Densification of Iron Powder, Mater. Sci. Eng. A, 2003, 359(1–2), p 119–128. https://doi.org/10.1016/S0921-5093(03)00341-1CrossRef

15.

H. Gong, K. Rafi, H. Gu, T. Starr and B. Stucker, Analysis of Defect Generation in Ti-6Al-4V Parts Made Using Powder Bed Fusion Additive Manufacturing Processes, Addit. Manuf., 2014, 1, p 87–98. https://doi.org/10.1016/j.addma.2014.08.002CrossRef

16.

S. Tabaie, F. Rézaï-Aria and M. Jahazi, Microstructure Evolution of Selective Laser Melted Inconel 718: Influence of High Heating Rates, Metals (Basel), 2020 https://doi.org/10.3390/met10050587CrossRef

17.

S. Li, H. Xiao, K. Liu, W. Xiao, Y. Li, X. Han, J. Mazumder and L. Song, Melt-Pool Motion, Temperature Variation and Dendritic Morphology of Inconel 718 During Pulsed- and Continuous-Wave Laser Additive Manufacturing: A Comparative Study, Mater. Des., 2017, 119, p 351–360. https://doi.org/10.1016/j.matdes.2017.01.065CrossRef

18.

T. Mukherjee, H.L. Wei, A. De and T. DebRoy, Heat and Fluid Flow in Additive Manufacturing—Part II: Powder Bed Fusion of Stainless Steel, and Titanium, Nickel and Aluminum Base Alloys, Comput. Mater. Sci., 2018, 150(April), p 369–380. https://doi.org/10.1016/j.commatsci.2018.04.027CrossRef

19.

M. Balbaa, S. Mekhiel, M. Elbestawi and J. McIsaac, On Selective Laser Melting of Inconel 718: Densification, Surface Roughness, and Residual Stresses, Mater. Des., 2020, 193, p 108818. https://doi.org/10.1016/j.matdes.2020.108818CrossRef

20.

L. Nastac, J.J. Valencia, M.L. Tims and F.R. Dax, Advances in the Solidification of IN718 and RS5 Alloys, Proc. Int. Symp. Superalloys Var. Deriv., 2001, 1, p 103–112. https://doi.org/10.7449/2001/superalloys_2001_103_112CrossRef

21.

V. Manvatkar, A. De and T. DebRoy, Spatial Variation of Melt Pool Geometry, Peak Temperature and Solidification Parameters During Laser Assisted Additive Manufacturing Process, Mater. Sci. Technol. (United Kingdom), 2015, 31(8), p 924–930. https://doi.org/10.1179/1743284714Y.0000000701CrossRef

22.

J.J. Lewandowski and M. Seifi, Metal Additive Manufacturing: A Review of Mechanical Properties, Annu. Rev. Mater. Res., 2016, 46, p 151–186. https://doi.org/10.1146/annurev-matsci-070115-032024CrossRef

23.

J. Yang, J. Han, Yu. Hanchen, J. Yin, M. Gao, Z. Wang and X. Zeng, Role of Molten Pool Mode on Formability, Microstructure and Mechanical Properties of Selective Laser Melted Ti-6Al-4V Alloy, Mater. Des., 2016, 110, p 558–570. https://doi.org/10.1016/j.matdes.2016.08.036CrossRef

24.

C. Kamath, Data Mining and Statistical Inference in Selective Laser Melting, Int. J. Adv. Manuf. Technol., 2016, 86(5–8), p 1659–1677. https://doi.org/10.1007/s00170-015-8289-2CrossRef

25.

K. Yuan, W.G. Guo, P. Li, J. Wang, Y. Su, X. Lin and Y. Li, Influence of Process Parameters and Heat Treatments on the Microstructures and Dynamic Mechanical Behaviors of Inconel 718 Superalloy Manufactured by Laser Metal Deposition, Mater. Sci. Eng. A, 2018, 721, p 215–225. https://doi.org/10.1016/j.msea.2018.02.014CrossRef

26.

Q. Jia and D. Gu, Selective Laser Melting Additive Manufactured Inconel 718 Superalloy Parts: High-Temperature Oxidation Property and its Mechanisms, Opt. Laser Technol., 2014, 62, p 161–171. https://doi.org/10.1016/j.optlastec.2014.03.008CrossRef

27.

T. Sanviemvongsak, D. Monceau and B. Macquaire, High Temperature Oxidation of IN 718 Manufactured by Laser Beam Melting and Electron Beam Melting: Effect of Surface Topography, Corros. Sci., 2018, 141(January), p 127–145. https://doi.org/10.1016/j.corsci.2018.07.005CrossRef

28.

H.L. Eiselstein, Metallurgy of a Columbium-Hardened Nickel-Chromium-Iron Alloy, in Advances in the Technology of Stainless Steels and Related Alloys, ASTM International, Pennsylvania, 2009, p 62–62–18

29.

H. Qi, M. Azer, and A. Ritter, “Studies of standard heat treatment effects on microstructure and mechanical properties of laser net shape manufactured INCONEL 718,” Metall. Mater. Trans. A Phys. Metall. Mater. Sci., vol. 40, no. 10, pp. 2410–2422, 2009, doi: https://doi.org/10.1007/s11661-009-9949-3

30.

P. Tao, H. Li, B. Huang, Q. Hu, S. Gong and Q. Xu, The Crystal Growth, Intercellular Spacing and Microsegregation of Selective Laser Melted Inconel 718 Superalloy, Vacuum, 2019, 159, p 382–390. https://doi.org/10.1016/j.vacuum.2018.10.074CrossRef

31.

E. Chlebus, K. Gruber, B. Kuźnicka, J. Kurzac and T. Kurzynowski, Effect of Heat Treatment on the Microstructure and Mechanical Properties of Inconel 718 Processed by Selective Laser Melting, Mater. Sci. Eng. A, 2015, 639, p 647–655. https://doi.org/10.1016/j.msea.2015.05.035CrossRef

32.

V. Manvatkar, A. De and T. Debroy, Heat Transfer and Material Flow During Laser-Assisted Multi-Layer Additive Manufacturing, J. Appl. Phys., 2014, 116(12), p 1–8. https://doi.org/10.1063/1.4896751CrossRef

33.

J. Li, Z. Zhao, P. Bai, H. Qu, B. Liu, L. Li, L. Wu, R. Guan, H. Liu and Z. Guo, Microstructural Evolution and Mechanical Properties of IN718 Alloy Fabricated by Selective Laser Melting Following Different Heat Treatments, J. Alloys Compd., 2019, 772, p 861–870. https://doi.org/10.1016/j.jallcom.2018.09.200CrossRef

34.

R. Priya Parida and V. Senthilkumar, Experimental Studies of Defect Generation in Selective Laser Melted Inconel 718 Alloy, Mater. Today Proc., 2021, 39(4), p 1372–1377. https://doi.org/10.1016/j.matpr.2020.04.698CrossRef

35.

P. Kumar, J. Farah, J. Akram, C. Teng, J. Ginn and M. Misra, Influence of Laser Processing Parameters on Porosity in Inconel 718 During Additive Manufacturing, Int. J. Adv. Manuf. Technol., 2019, 103(1–4), p 1497–1507. https://doi.org/10.1007/s00170-019-03655-9CrossRef

36.

A. Brown, Z. Jones, and W. Tilson, “Classification, Effects, and Prevention of Build Defects in Powder-Bed Fusion Printed Inconel 718,” 146th TMS 2017 Annu. Meet. Exhib., 2017

37.

B. Zhang, Y. Li and Q. Bai, Defect Formation Mechanisms in Selective Laser Melting: A Review, Chinese J. Mech. Eng., 2017, 30(3), p 515–527. https://doi.org/10.1007/s10033-017-0121-5CrossRef

38.

C. Qiu, N.J.E. Adkins and M.M. Attallah, Microstructure and Tensile Properties of Selectively Laser-Melted and of HIPed Laser-Melted Ti-6Al-4V, Mater. Sci. Eng. A, 2013, 578, p 230–239. https://doi.org/10.1016/j.msea.2013.04.099CrossRef

39.

M. Xia, D. Gu, G. Yu, D. Dai, H. Chen and Q. Shi, Porosity Evolution and its Thermodynamic Mechanism of Randomly Packed Powder-Bed During Selective Laser Melting of Inconel 718 Alloy, Int. J. Mach. Tools Manuf., 2017, 116, p 96–106. https://doi.org/10.1016/j.ijmachtools.2017.01.005CrossRef

40.

D. Gu and Y. Shen, Balling Phenomena in Direct Laser Sintering of Stainless Steel Powder: Metallurgical Mechanisms and Control Methods, Mater. Des., 2009, 30(8), p 2903–2910. https://doi.org/10.1016/j.matdes.2009.01.013CrossRef

41.

T. Larimian, M. Kannan, D. Grzesiak, B. AlMangour and T. Borkar, Effect of Energy Density and Scanning Strategy on Densification, Microstructure and Mechanical Properties of 316L Stainless Steel Processed via Selective Laser Melting, Mater. Sci. Eng. A, 2020, 770, p 138455. https://doi.org/10.1016/j.msea.2019.138455CrossRef

42.

B. AlMangour, D. Grzesiak, T. Borkar and J.M. Yang, Densification Behavior, Microstructural Evolution, and Mechanical Properties of TiC/316L Stainless Steel Nanocomposites Fabricated by Selective Laser Melting, Mater. Des., 2018, 138, p 119–128. https://doi.org/10.1016/j.matdes.2017.10.039CrossRef

43.

Y.N. Zhang, X. Cao, P. Wanjara and M. Medraj, Oxide Films in Laser Additive Manufactured Inconel 718, Acta Mater., 2013, 61(17), p 6562–6576. https://doi.org/10.1016/j.actamat.2013.07.039CrossRef

44.

X. Wang and K. Chou, Effects of Thermal Cycles on the Microstructure Evolution of Inconel 718 During Selective Laser Melting Process, Addit. Manuf., 2017, 18, p 1–14. https://doi.org/10.1016/j.addma.2017.08.016CrossRef

45.

H. Yang, L. Meng, S. Luo and Z. Wang, Microstructural Evolution and Mechanical Performances of Selective Laser Melting Inconel 718 from Low to High Laser Power, J. Alloys Compd., 2020, 828, p 154473. https://doi.org/10.1016/j.jallcom.2020.154473CrossRef

46.

Y.L. Kuo, S. Horikawa and K. Kakehi, The Effect of Interdendritic δ Phase on the Mechanical Properties of Alloy 718 Built up by Additive Manufacturing, Mater. Des., 2017, 116, p 411–418. https://doi.org/10.1016/j.matdes.2016.12.026CrossRef

47.

H.L. Wei, J. Mazumder and T. DebRoy, Evolution of Solidification Texture During Additive Manufacturing, Sci. Rep., 2015, 5, p 1–7. https://doi.org/10.1038/srep16446CrossRef

Title: Effect of Scan Speed and Laser Power on the Nature of Defects, Microstructures and Microhardness of 3D-Printed Inconel 718 Alloy
Authors: Pravin Kumar
P. Chakravarthy
Sushant K. Manwatkar
S. V. S. Narayana Murty
Publication date: 26-08-2021
Publisher: Springer US
Published in: Journal of Materials Engineering and Performance / Issue 9/2021
Print ISSN: 1059-9495
Electronic ISSN: 1544-1024
DOI: https://doi.org/10.1007/s11665-021-06163-8

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 9/2021

Investigation of Spatters in Cold Metal Transfer + Pulse-Based Wire and Arc Additive Manufacturing of High Nitrogen Austenitic Stainless Steel

Studying the Microstructural Effect of Selective Laser Melting and Electropolishing on the Performance of Maraging Steel

Production of Bioactive Various Lattices as an Artificial Bone Tissue by Digital Light Processing 3D Printing

Effect of Conventional Heat Treatments on the Microstructure and Microhardness of IN718 Obtained by Wrought and Additive Manufacturing

Effect of WC Composition on the Microstructure and Surface Properties of Laser Directed Energy Deposited SS 316-WC Composites

Modeling the Tensile Behavior of Specimens Manufactured by the Selective Laser Melting Method Using Continuum Damage Mechanics Theory

Premium Partners