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Nikki Harless
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Proceedings Papers
AM-EPRI2024, Advances in Materials, Manufacturing, and Repair for Power Plants: Proceedings from the Tenth International Conference, 338-354, October 15–18, 2024,
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Inconel 718 is a nickel-based superalloy known for its excellent combination of high-temperature strength, corrosion resistance, and weldability. Additive Manufacturing (AM) has revolutionized traditional manufacturing processes by enabling the creation of complex and customized components. In this work, three prominent AM techniques: Laser-Based Powder Bed Fusion (PBF), Wire Direct Energy Deposition (DED), and Binder Jet (BJ) processes were explored. A thorough metallographic analysis and comparison of samples was conducted after short-term creep testing originating from each of the three aforementioned techniques in addition to wrought material. Detailed electron microscopy unveiled equiaxed grains in both BJ and wrought samples while PBF samples displayed elongated finer grain structures in the build direction, characteristic of PBF. The DED samples revealed a more bimodal grain distribution with a combination of smaller equiaxed grains accompanied by larger more elongated grains. When assessing the three processes, the average grain size was found to be larger in the BJ samples, while the PBF samples exhibited the most significant variation in grain and sub-grain size. Number density, size, and shape of porosity varied between all three techniques. Post-creep test observations in PBF samples revealed the occurrence of wedge cracking at the failure point, accompanied by a preference for grain boundary creep void formation while BJ samples exhibited grain boundary creep void coalescence and cracking at the failure location. In the DED samples, void formation was minimal however, it seemed to be more prevalent in areas with precipitates. In contrast, the wrought sample showed void formation at the failure site with a preference for areas with primary carbide formation. Despite BJ samples demonstrating similar or even superior rupture life compared to other AM techniques, a noteworthy reduction in rupture ductility was observed. While a coarse, uniform grain size is generally linked to enhanced creep resistance and rupture life, the combination of pre-existing voids along grain boundaries and the formation of new voids is hypothesized to accelerate rapid fracture, resulting in diminished ductility. This research shows careful consideration is needed when selecting an AM technology for high- temperature applications as creep behavior is sensitive to the large microstructural variations AM can introduce.