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Additive Manufacturing of Superalloys
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Additive Manufacturing of Superalloys

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 11177

Special Issue Editors

Prof. Dr. Shrikant Joshi

E-Mail Website
Guest Editor
Department of Engineering Science, University West, Trollhättan, Sweden
Interests: suspension and solution plasma spraying; HVAF spraying; thermal barrier coatings; coatings for wear and corrosion; additive manufacturing; electron beam melting; laser metal deposition; post-treatment
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Joel Andersson

E-Mail Website
Guest Editor
Department of Engineering Science, University West, Trollhättan, Sweden
Interests: additive manufacturing; welding and weldability testing; materials engineering and materials physics
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Additive manufacturing (AM) is widely acknowledged as a disruptive technology particularly well-suited for the production of complexly shaped components from traditionally difficult-to-machine materials such as superalloys. There is also a growing realization that future innovative turbine designs will rely heavily on harnessing the multiple benefits of AM to fabricate superalloy parts with advanced geometries. Consequently, there is considerable present-day focus on exploring varied facets of different AM technologies to enhance scientific understanding of important associated aspects to accelerate their industrial adoption. The enormous investment of time and research effort have been responsible for continuous developments across the board and led to growing optimism regarding deployment of AM techniques for manufacture and repair of superalloy components.

The proposed Special Issue of Materials seeks to showcase prominent new developments in the field of AM of superalloys. Contributions are particularly invited from, but not limited to, those of you who are actively involved in (i) alloy design; (ii) powder production and pre-processing; (iii) process parameter impact and optimization; (iv) post-processing of builds, spanning HIPing, heat treatment, machining, welding etc.; (v) advanced characterization; (vi) residual stress and distortion; (vii) mechanical and functional property assessment; (viii) process–microstructure–property correlations; (ix) modeling; (x) process reliability and qualification; and (xi) applications.

Prof. Dr. Shrikant Joshi
Prof. Dr. Joel Andersson
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • additive manufacturing (AM)
  • powder bed fusion (PBF)
  • direct metal deposition (DMD)
  • electron beam powder bed fusion (EB–PBF)
  • laser-based powder bed fusion (L-PBF)
  • processing
  • post-treatment
  • characterization
  • mechanical properties
  • functional properties
  • modeling
  • diagnostics
  • monitoring
  • applications

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Published Papers (3 papers)

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Research

14 pages, 23246 KiB  
Article
Semi-Hybrid CO2 Laser Metal Deposition Method with Inter Substrate Buffer Zone
by Bogdan Antoszewski, Hubert Danielewski, Jan Dutkiewicz, Łukasz Rogal, Marek St. Węglowski, Krzysztof Kwieciński and Piotr Śliwiński
Materials 2021, 14(4), 720; https://doi.org/10.3390/ma14040720 - 4 Feb 2021
Cited by 1 | Viewed by 1950
Abstract
This article presents the results of the metal deposition process using additive materials in the form of filler wire and metal powder. An important problem in wire deposition using a CO2 laser was overcome by using a combination of the abovementioned methods. [...] Read more.
This article presents the results of the metal deposition process using additive materials in the form of filler wire and metal powder. An important problem in wire deposition using a CO2 laser was overcome by using a combination of the abovementioned methods. The deposition of a multicomponent alloy—Inconel 625—on a basic substrate such as structural steel is presented. The authors propose a new approach for stopping carbon and iron diffusion from the substrate, by using the Semi-Hybrid Deposition Method (S-HDM) developed by team members. The proposed semi-hybrid method was compared with alternative wire and powder deposition using laser beam. Differences of S-HDM and classic wire deposition and powder deposition methods are presented using metallographic analysis, within optic and electron microscopy. Significant differences in the obtained results reveal advantages of the developed method compared to traditional deposition methods. A comparison of the aforementioned methods performed using nickel based super alloy Inconel 625 deposited on low carbon steel substrate is presented. An alternative prototyping approach for an advanced high alloy materials deposition using CO2 laser, without the requirement of using the same substrate was presented in this article. This study confirmed the established assumption of reducing selected components diffusion from a substrate via buffer layer. Results of metallographic analysis confirm the advantages and application potential of using the new semi-hybrid method for prototyping high alloy materials on low alloy structural steel substrate. Full article
(This article belongs to the Special Issue Additive Manufacturing of Superalloys)
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21 pages, 20855 KiB  
Article
On the Microstructure of Laser Beam Powder Bed Fusion Alloy 718 and Its Influence on the Low Cycle Fatigue Behaviour
by Arun Ramanathan Balachandramurthi, Nitesh Raj Jaladurgam, Chamara Kumara, Thomas Hansson, Johan Moverare, Johannes Gårdstam and Robert Pederson
Materials 2020, 13(22), 5198; https://doi.org/10.3390/ma13225198 - 17 Nov 2020
Cited by 8 | Viewed by 3456
Abstract
Additive manufacturing of Alloy 718 has become a popular subject of research in recent years. Understanding the process-microstructure-property relationship of additively manufactured Alloy 718 is crucial for maturing the technology to manufacture critical components. Fatigue behaviour is a key mechanical property that is [...] Read more.
Additive manufacturing of Alloy 718 has become a popular subject of research in recent years. Understanding the process-microstructure-property relationship of additively manufactured Alloy 718 is crucial for maturing the technology to manufacture critical components. Fatigue behaviour is a key mechanical property that is required in applications such as gas turbines. Therefore, in the present work, low cycle fatigue behaviour of Alloy 718 manufactured by laser beam powder bed fusion process has been investigated. The material was tested in as-built condition as well as after two different thermal post-treatments. Three orientations with respect to the building direction were tested to evaluate the anisotropy. Testing was performed at room temperature under controlled amplitudes of strain. It was found that defects, inclusions, strengthening precipitates, and Young’s modulus influence the fatigue behaviour under strain-controlled conditions. The strengthening precipitates affected the deformation mechanism as well as the cycle-dependent hardening/softening behaviour. The defects and the inclusions had a detrimental effect on fatigue life. The presence of Laves phase in LB-PBF Alloy 718 did not have a detrimental effect on fatigue life. Young’s modulus was anisotropic and it contributed to the anisotropy in strain-life relationship. Pseudo-elastic stress vs. fatigue life approach could be used to handle the modulus-induced anisotropy in the strain-life relationship. Full article
(This article belongs to the Special Issue Additive Manufacturing of Superalloys)
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12 pages, 35593 KiB  
Communication
A Novel γ′-Strengthened Nickel-Based Superalloy for Laser Powder Bed Fusion
by Jinghao Xu, Hans Gruber, Ru Lin Peng and Johan Moverare
Materials 2020, 13(21), 4930; https://doi.org/10.3390/ma13214930 - 2 Nov 2020
Cited by 21 | Viewed by 4436
Abstract
An experimental printable γ′-strengthened nickel-based superalloy, MAD542, is proposed. By process optimization, a crack-free component with less than 0.06% defect was achieved by laser powder bed fusion (LPBF). After post-processing by solution heat treatment, a recrystallized structure was revealed, which was also associated [...] Read more.
An experimental printable γ′-strengthened nickel-based superalloy, MAD542, is proposed. By process optimization, a crack-free component with less than 0.06% defect was achieved by laser powder bed fusion (LPBF). After post-processing by solution heat treatment, a recrystallized structure was revealed, which was also associated with the formation of annealing twins. After the aging treatment, 60–65% γ′ precipitates were obtained with a cuboidal morphology. The success of printing and post-processing the new MAD542 superalloy may give new insights into alloy design approaches for additive manufacturing. Full article
(This article belongs to the Special Issue Additive Manufacturing of Superalloys)
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