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Role of Processing in Microstructural Evolution in Inconel 625: A Comparison of Three Additive Manufacturing Techniques

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Abstract

Additive manufacturing (AM) processes have widely varying thermal environments, which dictate the solidification of alloys during solidification. Here, we use binder jet 3D printing (BJ3DP), electron beam freeform fabrication (EBF3), and direct metal laser sintering (DMLS) to fabricate samples of Inconel 625, displaying the significant differences in microstructure brought about purely by the thermal gradients produced in each manufacturing method. Dislocation density and elastic strain are measured using high-resolution electron backscatter diffraction and the spatial relationship between these features is analyzed with respect to the relative thermal environments of each AM technique, with DMLS exhibiting microstructure typical of high thermal gradients and rapid solidification. Increasing thermal gradient and solidification rate results in a stronger spatial dependence of microscale elastic strain on GND density. Our results also demonstrate the use of statistical techniques to quantify microstructural features in relation to processing, which has potential for informing frameworks which can predict microstructure and material properties of AM components.

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Acknowledgments

The authors would like to acknowledge the team at Hoeganaes Corp. in Cinnaminson, N.J., particularly Alex Zwiren and George Bernhard, for fabrication of the BJ3DP sample, Jacob Hochhalter at NASA Langley Research Center in Hampton, VA, for fabrication of the EBF3 sample, and Matthew Clemente and Elias Jelis at Army ARDEC at Picatinny Arsenal, N.J., for DMLS manufacturing.

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  1. Department of Materials Science and Engineering, Johns Hopkins University, Baltimore, MD, 21218, USA

    Kathryn A. Small & Mitra L. Taheri

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Manuscript submitted October 30, 2020; accepted March 26, 2021.

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Small, K.A., Taheri, M.L. Role of Processing in Microstructural Evolution in Inconel 625: A Comparison of Three Additive Manufacturing Techniques. Metall Mater Trans A 52, 2811–2820 (2021). https://doi.org/10.1007/s11661-021-06273-x

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