Metallurgical and Materials Transactions A

, Volume 49, Issue 9, pp 3764–3780 | Cite as

Additive Manufacturing of Nickel Superalloys: Opportunities for Innovation and Challenges Related to Qualification

  • S. S. Babu
  • N. Raghavan
  • J. Raplee
  • S. J. Foster
  • C. Frederick
  • M. Haines
  • R. Dinwiddie
  • M. K. Kirka
  • A. Plotkowski
  • Y. Lee
  • R. R. Dehoff
Topical Collection: Superalloys and Their Applications
Part of the following topical collections:
  1. Third European Symposium on Superalloys and their Applications


Innovative designs for turbines can be achieved by advances in nickel-based superalloys and manufacturing methods, including the adoption of additive manufacturing. In this regard, selective electron beam melting (SEBM) and selective laser melting (SLM) of nickel-based superalloys do provide distinct advantages. Furthermore, the direct energy deposition (DED) processes can be used for repair and reclamation of nickel alloy components. The current paper explores opportunities for innovation and qualification challenges with respect to deployment of AM as a disruptive manufacturing technology. In the first part of the paper, fundamental correlations of processing parameters to defect tendency and microstructure evolution will be explored using DED process. In the second part of the paper, opportunities for innovation in terms of site-specific control of microstructure during processing will be discussed. In the third part of the paper, challenges in qualification of AM parts for service will be discussed and potential methods to alleviate these issues through in situ process monitoring, and big data analytics are proposed.



This research is based upon work supported by the US Department of Energy, Office of Energy, Efficiency, and Renewable Energy, Advanced Manufacturing Office under Contract Number DE-AC05-00OR22725. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( downloads/doe-public-access-plan


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Copyright information

© The Minerals, Metals & Materials Society and ASM International 2018

Authors and Affiliations

  • S. S. Babu
    • 1
  • N. Raghavan
    • 2
  • J. Raplee
    • 3
  • S. J. Foster
    • 4
  • C. Frederick
    • 1
  • M. Haines
    • 1
  • R. Dinwiddie
    • 2
  • M. K. Kirka
    • 2
  • A. Plotkowski
    • 2
  • Y. Lee
    • 2
  • R. R. Dehoff
    • 2
  1. 1.Mechanical, Aerospace and Biomedical Engineering, The University of TennesseeKnoxvilleUSA
  2. 2.Oak Ridge National LaboratoryOak RidgeUSA
  3. 3.ArconicPittsburgUSA
  4. 4.OerlikonCharlotteUSA

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