Geometry-Induced Spatial Variation of Microstructure Evolution During Selective Electron Beam Melting of Rene-N5

High gamma prime (γ′) nickel-based alloys produced by selective electron beam melting are of interest to the turbine industry which requires control of microstructure in relation to loading conditions within complex component geometry. Welding literature predicts cracking and microstructure evolution as a function of alloy composition and process parameters in this class of alloys. In addition, Additive manufacturing causes variations in the above conditions due to the interaction of geometry on processing and heat transfer. The influence of geometry on processing conditions was explored for alloy Rene N5 by characterizing the solidification grain microstructure and solid-state precipitation. A Semi-Analytical Heat Transfer Model was employed to explain the resulting variation in solidification grain morphology that occurred due to the part geometry. The as-built precipitation structure was found to vary as a function of build height and had no correlation to the solidification grain structure or the layer geometry.