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<p>A special investigation was carried out to characterize the differences in microstructure, heat treatment response, and mechanical properties of alloys fabricated by different additive manufacturing (AM) processes. A systematic study was conducted base on a high γ′-content AM-ed Ni superalloy AMSC-DB fabricated by Laser Powder Bed Fusion (L-PBF) and Laser Direct Energy Deposition (L-DED) processes. Microstructural results show that the L-PBF sample exhibits refined grains, suppression of precipitation mechanism of the γ′ phase and carbides formation, and significant accumulation of residual stress compared with the as-printed L-DED sample, primarily due to the extremely rapid cooling rate in the L-PBF process. Based on the microstructural differences, the heat treatment processes have been optimized accordingly, which manage to manipulate the precipitation and recrystallization behavior in the formed layers. The coarser grains and carbides in the L-DED samples were shown to effectively hinder crack propagation along grain boundaries, thereby yielding superior creep-rupture performance at 900&#xa0;°C/200&#xa0;MPa compared with the case of L-PBF sample. As a result, this research shed light on the design of heat treatment processes for the used type of compositionally complex Ni superalloys and the application of AM technology/material combinations for the two most widely applied AM techniques with intensive laser heating.</p>

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Microstructure and mechanical properties of Ni superalloy fabricated by laser directed energy deposition (L-DED) versus laser powder bed fusion (L-PBF)

  • 期刊论文

  • 发表日期：

    2026年4月22日

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  • Xingming Yang,
  • Jiabo Fu,
  • Yanzhen Hu,
  • Andrei Vasilievitch Gorbunov,
  • Oleg Devojno,
  • Minghao Huang,
  • Hao Yu,
  • Wei Xu

摘要

A special investigation was carried out to characterize the differences in microstructure, heat treatment response, and mechanical properties of alloys fabricated by different additive manufacturing (AM) processes. A systematic study was conducted base on a high γ′-content AM-ed Ni superalloy AMSC-DB fabricated by Laser Powder Bed Fusion (L-PBF) and Laser Direct Energy Deposition (L-DED) processes. Microstructural results show that the L-PBF sample exhibits refined grains, suppression of precipitation mechanism of the γ′ phase and carbides formation, and significant accumulation of residual stress compared with the as-printed L-DED sample, primarily due to the extremely rapid cooling rate in the L-PBF process. Based on the microstructural differences, the heat treatment processes have been optimized accordingly, which manage to manipulate the precipitation and recrystallization behavior in the formed layers. The coarser grains and carbides in the L-DED samples were shown to effectively hinder crack propagation along grain boundaries, thereby yielding superior creep-rupture performance at 900 °C/200 MPa compared with the case of L-PBF sample. As a result, this research shed light on the design of heat treatment processes for the used type of compositionally complex Ni superalloys and the application of AM technology/material combinations for the two most widely applied AM techniques with intensive laser heating.