Nickel-based Inconel 625 is widely used for both low and high-temperature applications. It has several applications in aerospace, marine, chemical, and petrochemical industries due to its high strength, corrosion resistance, good formability, and weldability. With the molten pool’s rapid solidification during laser powder bed fusion (LPBF), the resulting microstructures differ from those expected in equilibrium conditions. Residual stresses, microsegregation, anisotropy, undesirable phases, layered structure, and lower mechanical properties are the challenges that must be addressed before LPBF-ed Inconel 625 parts can be industrially implemented. Heat treatment of Inconel 625 after the LPBF process is widely discussed in the literature, and the proposed heat treatment processes do not address all the challenges mentioned above. For this reason, specific heat treatments should be designed to achieve desired mechanical properties. Five different high-temperature heat treatment procedures were developed and tested in recent work in comparison with the standard heat treatment for wrought alloy (AMS 5599), to study the effect of various heat treatment parameters on the type of precipitates, grain size, room, and elevated temperature mechanical properties, and to develop an elevated-temperature tensile curve between room temperature (RT) and 760°C of LPBF-ed Inconel 625. Four heat treatment procedures showed complete recrystallization and the formation of equiaxed grain size containing annealed twins and carbide precipitates. However, either eliminating the stress relief cycle or conducting it at a lower temperature resulted in microstructures having the same pool deposition morphology with grains containing dendritic microstructure and epitaxial grains. Two different grain sizes could be obtained, starting with the same as-built microstructure by controlling post-process heat treatment parameters. The first type, coarse grain size (ASTM grain size No. G 4.5), suitable for creep application, was achieved by applying hot isostatic pressing (HIP) followed by solution annealing. The second type, fine-grain size (ASTM grain size No. G 6), preferable for fatigue properties, was achieved by applying solution annealing followed by HIP. The mechanical properties at room and elevated temperature 540°C are higher than the available properties in the AMS 5599 for wrought Inconel 625 while maintaining a higher ductility above the average level found in the standards. It can be concluded that the performed heat treatment achieves higher mechanical properties. The values of ultimate tensile strength (UTS), yield strength (YS), elongation, and reduction of area percentages are similar in the XZ and XY orientations, revealing the presence of isotropic microstructure. The ultimate tensile strength values show an anomalous behavior as a function of the temperature. From the room temperature until around 500°C, there occurs a decrease in the yield strength and a slight increase up to 600°C, decreasing sharply at 700°C. An anomaly is also present in relation to the elongation, with a significant decrease in the elongation at temperatures after 600°C.

As more industries look toward additively manufactured (AM) components to combat lead times, re-design, cost of complexity, etc., those industries are faced with re-evaluating the performance of AM-based materials as compared to their well-documented wrought or machined counterparts. A particular alloy of interest to many industries including aerospace and energy/power generation is Inconel 718 due to its resistance to oxidation and high temperature degradation [1]. Additively manufactured Inconel 718 parts typically receive a series of post-build heat treatments prior to deployment. If not properly controlled, these post-build treatments may introduce secondary precipitates and other inhomogeneities that will affect the parts’ mechanical properties and susceptibility to corrosion. This is specifically true of susceptibility to localized corrosion mechanisms that may lead to crack initiation, accelerated crack growth and ultimately premature failure. By utilizing electrochemical parameter testing to analyze for localized breakdown potentials, this work investigates the variation in tolerance to localized corrosion that results from common post-build heat treatment steps and the secondary phase precipitation that can ensue in Inconel 718 AM parts.

IN718 has good fabricability, high strength at elevated temperature, and corrosion resistance, and it is widely deployed in many aerospace and other high-performance applications. With the molten pool rapid solidification during laser powder bed fusion (L-PBF), the resulting microstructure is anisotropic and inhibits macro-segregation. The as-built condition usually exhibits lower mechanical properties. Four different heat treatment procedures were designed and tested to study the effect of different heat treatment parameters on the type of precipitates and grain size. The investigated heat treatment procedures showed the formation of equiaxed grain size and a significant amount of γ' and γ" particles at the grain boundary in addition to primary carbide types (MC). Three types of microstructure characteristics and grain size were achieved. Coarse grain size suitable for creep application was achieved by increasing the soaking time at the aging cycle. The formation of serrated grain boundaries suitable for good fatigue and creep properties was achieved by decreasing the stress relief cycle's soaking time and temperature. Fine-grain size, which is preferable for fatigue properties, was achieved by decreasing the soaking time at the solution annealing cycle.

Hastelloy X is used in turbomachinery and petrochemical applications as it is designed for excellent oxidation and stress corrosion cracking resistance, strength, and stress rupture behavior. This alloy is now being printed via powder bed fusion processes as many industries have developed interests in the benefits additive manufacturing (AM) offers. However as-printed Hastelloy X suffers from material defect formation such as hot cracking. Hot isostatic pressing (HIP) is often applied to improve performance and reliability. Although the conventional HIP process has been shown to eliminate defects, the equipment is unable to cool at desired rates allowing the formation of excessive carbide precipitation, negatively influencing corrosion resistance and toughness. In turn the product is solution treated at a similar temperature while applying rapid gas cooling for performance requirements. With use of uniform rapid cooling available in modern HIP equipment, a high-pressure heat treatment can be applied offering the ability to perform both HIP and heat treatment in one piece of equipment. Microstructure and tensile properties are evaluated and compared to the conventional processing routes. The results demonstrate that the novel high pressure heat treatment approach offers a processing route that is equivalent to or better than conventional methods.

Hydrogen embrittlement (HE) susceptibility was investigated for Alloy 718 and Alloy 945X specimens heat treated to a set of conditions within the specifications of API Standard 6ACRA. Heat treatments were selected to simulate the potential variation in thermal history in thick sections of bar or forged products and produce various amounts of discontinuous grain boundary δ phase in Alloy 718 and M 23 C 6 carbides in Alloy 945X, while maintaining a constant hardness in the range of 35-45 HRC for Alloy 718 and 34-42 HRC for Alloy 945X. Time-temperature-transformation (TTT) diagrams and experimentation were used to select a set of heat treatments containing no δ phase, a small quantity of δ, and a larger quantity of δ in Alloy 718. The presence of δ phase has not been verified for the moderate condition. A similar approach was taken regarding M 23 C 6 carbides in Alloy 945X. Incremental step loading (ISL) tests were conducted under in-situ cathodic charging on circular notch tensile (CNT) specimens in a 0.5 M H2SO4 solution. During the test, the direct current potential drop (DCPD) was measured across the notch to determine the stress intensity associated with unstable crack growth. Results indicate that even very small quantities of δ phase in Alloy 718 are detrimental to HE resistance. Both Alloy 718 and Alloy 945X show decreases in HE resistance with aging, with a greater degradation in Alloy 718.

The work presented in this paper addresses a data gap that continues to be a hinderance to users of precipitation modeling tools, particularly those based on Langer-Schwartz theory. Thermodynamic and kinetic data required for precipitation models can be obtained from CALPHAD databases, but interfacial energies between the bulk and precipitate phases are not available for many alloy systems. In this work, a number of matrix-precipitate interfacial energies have been determined for influential precipitates in alloys of industrial importance, for example, carbides in Grade 22 low-alloy steels, delta phase in Ni 625 and 718, S-phase in Al 2024, and Q’ and β’’ in Al 6111.

Rene 65 is a nickel-based superalloy used in aerospace components such as turbine blades and disks. The microstructure in the as-received condition of the superalloy consists of about 40% volume fraction of gamma prime precipitates, which is so strong that thermomechanical processing is problematic. The aim of this work is to find a heat treatment to reduce hardness for manufacturing purposes without changing grain size in the final application. For the design of the heat treatments, Taguchi’s L8 matrix is used and the factors that are examined include cooling rate, hold temperature, hold time, and cooling method to room temperature.

Laser powder bed fusion (L-PBF) is an additive manufacturing (AM) technique through which net shape/near-net components are built by selectively melting powder, one layer at a time, with a focused laser beam. The as-built microstructures have a great impact on the phase transformation and precipitation behavior during subsequent heat treatment. This study was directed to understand the effect of component thickness, in the case of complex shape components, on the microstructure, type of precipitates of L-PBF IN 718 in as-built and heat-treated conditions. Standard heat treatment cycles per ASTM F3055 and AMS 2774D were investigated. This work shows that microstructure, grain size, types of precipitates, and formed phases of components produced by L-PBF in the as-built condition and after heat treatment are profoundly different with different component thicknesses. In order to obtain the optimal microstructure and mechanical properties, specific heat treatments are necessary due to the complexity of the components produced.

In this paper a novel nickel-base, alumina forming alloy, Nikrothal PM 58 is introduced. Similar to the previously developed, ferritic, iron-base alloy Kanthal APMT, the alloy bases its corrosion resistance on the formation of an adherent surface alumina layer. They both have high creep strength, due to a dispersion strengthened microstructure from the powder metallurgical processing route. This unique combination of properties enables application temperatures ranging from 1472 F (800°C) to 2372 F (1300°C) and new possibilities to design high temperature components like mesh belts, furnace rollers and muffles. Mechanical and corrosion properties for Nikrothal PM 58 at 2012 F (1100°C) and 2192 F (1200°C) are presented and compared with other commercial high temperature alloys.

Extension of the service life for high temperature structural alloy RA602CA is the goal for the project described in this paper. The performance of alloy RA602CA and aluminized RA602CA in a gas carburization furnaces were studied for periods up to two years. Aluminizing treatments (widely used in aerospace industry, especially in turbine blade applications) were also studied in this project. Carbon has very low solubility in alumina, so aluminizing could be a good method for protecting RA602CA alloys. Microstructural development during the carburizing process is presented, and the degradation of chromium oxide as well as alumina oxides is identified. The weight gain of RA602CA compared to similar alloys is discussed.

The most common probe used for cooling curve analysis of quenchants is a 12.5 mm diameter x 60 mm Inconel 600 cylindrical probe with a Type K thermocouple inserted into the geometric center. The time-temperature cooling curve is obtained at this position and is the basis for national and international standards including ASTM D6200, D6482, D6549, ISO 9950 and others. However, greater insight into the quenching process would be possible if a better profile were available for the uniformity and wetting kinematics of the quenching process. An alternative probe design, proposed by Prof. H.M. Tensi and his colleagues, utilizes a cylindrical 15 mm diameter x 45 mm flat-bottom shape with four thermocouples. One thermocouple is inserted to the geometric center of the probe at 22.5 mm from the bottom. The remaining three thermocouples are located 2 mm below the surface of the probe at 2 mm, at 15 mm, and at 30 mm from the bottom. This alternative probe design was used to characterize the usual centerline cooling curve properties as well as rewetting properties of two vegetable oils, palm oil and canola oil, a commercial fast petroleum oil quenchant, and a conventional petroleum oil quenchant. The probe construction, use, and quenching characterization results are reviewed in this paper.

Performances of quenchants have been enhanced and maintained based on their cooling characteristics determined by specific test systems. A rotary-arm type test system with a small ball probe has been developed for this purpose by making prototypes. Its unique concept derived mainly from a circular motion of a small ball probe in quenchants was proposed by Tawara in 1941. The prototypes have been realized by current heating, measuring and mechatronics techniques. Finally the probe material has been changed from nickel alloy to platinum for resolving the discoloration and thermal aging problems on the probe surface. The performance of the prototypes has been verified by systematic tests using specific quenchants under various cooling conditions.

An advanced nickel alloy with a specially designed chemistry to provide maximum oxidation resistance at the most extreme temperatures and controlled precipates to maximize creep strength. A leading vacuum furnace supplier has selected this alloy as a suitable material for bar baskets in their most demanding application, 2300 F and pressure quenching. Baskets fabricated from all other alloys tested lasted between 5 and 10 cycles before requiring extensive, labor intensive straightening. The new alloy baskets have been used for over 30 cycles, with minimal distortion. This extended life eliminates several straightening cycles and the high labor costs associated with manual straightening and reassembly.

RA 602 CA (also known as 602 CA and NiCroFer 6025, which are trademarks of VDM) is one of the best heat resistant alloys. It has excellent creep strength even at high temperatures, and oxidation resistance up to 2250°F. It is being used in an increasing number of new applications in the toughest of high temperature environments with success.

The heat-treating industry is in need of heat-treatment furnace materials and fixtures that have a long service life and reduced heat capacity. Failure mechanisms on the effect of prolonged exposure to carburization heat treatment have been investigated. RA330, RA602CA, 304L, 316L and Inconel 625 alloys were selected to study the anti-corrosion properties. The alloys were exposed to 0.7%C carburizing atmosphere at around 900°C for 3 months, 6months, and 12months. Based on microstructural analysis of components that were used until failure in carburization furnace application, it was found that the primary reason for failure was the excessive carburization that leads to “metal dusting” and subsequent cracking. In addition, metallographic analysis indicated that “flake offs” of Fe-Cr-Ni alloys were mainly graphite and chromium carbides. In this paper the failure analysis of industrial components will be presented. In addition, the preliminary analysis of microstructural development during long term exposure experiments in an industrial carburizing furnace will be presented. These samples were characterized using optical and scanning electron microscope and x-ray diffraction.

HR-120TM alloy is a Ni-Fe-Cr alloy designed to have high strength at elevated temperature and resistance to attack in carburizing and sulfidizing environments. Applications for this alloy include components to be assembled in combustion turbines for power generation. Some of these components can be manufactured by ring-rolling procedures followed by heat treating operations. Typically, HR-120TM alloy is heat-treated in a temperature range of 1175 to 1230°C in order to promote microstructure homogenization and dissolution of heavy precipitates. An inconvenience of such heat-treating temperature range is related to excessive grain-size coarsening of wrought parts. This work presents the results of a series of heat-treatment procedures performed on seamless rings produced by ring-rolling considering industrial conditions. Lower heat-treatment temperatures are considered for evaluation of mechanical and microstructural properties. It is reported that an excellent combination of mechanical properties and microstructural characteristics is obtained when alloy is exposed to 1050°C for soaking periods above 30 minutes.