Investigating the influence of process parameters on the structural integrity of an additively manufactured nickel-based superalloy

Abstract

Additive manufacturing (AM) is a novel near net shape manufacturing technology that joins metallic powders layer upon layer in conjunction with 3D model data and as such offers tremendous potential to a wide range of industrial sectors given its ability to produce highly intricate components with very little material wastage. Subsequently, the aerospace industry has become particularly interested in utilising AM as a means of manufacturing nickel-based superalloys for high-temperature applications, such as non-rotating components within gas turbine engines, which are traditionally fabricated through traditional cast and wrought methodologies. As a result of this, a detailed understanding of the influence of key process variables on the structural integrity of the different experimental builds is required. A semi-empirical quantitative approach for melt track analysis has been conducted and the impact on melt track sizing and defect forming mechanisms in the as-built and heat-treated condition is investigated.