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Asymmetric Cracking in Mar-M247 Alloy Builds During Electron Beam Powder Bed Fusion Additive Manufacturing

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Abstract

In the electron beam powder bed fusion (EB-PBF) process, a substantial number of high-gamma prime Ni-based superalloys are considered as non-printable due to a high propensity to form cracks. In this research, we focused on computational modeling framework to predict solidification-related cracking phenomena in EB-PBF processes. The cracking analysis was performed on cylindrical overhang structures where the cracks are observed only on one side of the part. Comprehensive microstructural characterization correlated the cracking tendency to low-melting point liquid-film formation along columnar grain boundaries with high misorientation angles due to partitioning of alloying elements. Uncoupled numerical thermal and mechanical models were used to rationalize the relationship between process parameters, build geometry, and cracking. The simulations showed asymmetric temperature distributions and associated asymmetric tensile thermal stresses over a cross section due to differences in section modulus and periodic changes in beam scanning directions. The results provide a potential pathway based on spatially varying beam scanning strategies to reduce the cracking tendency during additive manufacturing of complex geometries on the overhang structure in high-gamma prime nickel-based superalloys.

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Notes

  1. Identification of the powder producers should not be considered as the endorsement.

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Acknowledgments

The research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office under contract DE-AC05-00OR22725 with UT-Battelle, LLC. The authors thank Dr. Alex Plotkowski of ORNL for constructive criticism.

Author information

Authors and Affiliations

  1. Manufacturing Demonstration Facility, Oak Ridge National Laboratory, Knoxville, TN, 37932, USA

    Y. S. Lee, M. M. Kirka, S. Kim, N. Sridharan, A. Okello, R. R. Dehoff & S. S. Babu

  2. Materials Science and Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, 37830, USA

    Y. S. Lee, M. M. Kirka, S. Kim, N. Sridharan, A. Okello & R. R. Dehoff

  3. Department of Mechanical, Aerospace and Biomedical Engineering, University of Tennessee, Knoxville, TN, 37916, USA

    S. S. Babu

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  1. Y. S. Lee
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  4. N. Sridharan
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  5. A. Okello
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Correspondence to Y. S. Lee.

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Notice of Copyright. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. 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 (http://energy.gov/downloads/doe-public-access-plan).

Manuscript submitted February 7, 2018.

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Lee, Y.S., Kirka, M.M., Kim, S. et al. Asymmetric Cracking in Mar-M247 Alloy Builds During Electron Beam Powder Bed Fusion Additive Manufacturing. Metall Mater Trans A 49, 5065–5079 (2018). https://doi.org/10.1007/s11661-018-4788-8

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