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Creep performance of a modified version of Haynes 230 processed with laser powder bed fusion
McConville, Daniel P., Jr.
McConville, Daniel P., Jr.
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2024
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2026-04-04
Abstract
Ni-based superalloys processed by laser beam powder bed fusion (PBF-LB) additive manufacturing (AM) are ideal for the aerospace and power generation industries due to the increased component complexity and part consolidation afforded by AM. However, some alloys exhibit solidification cracking when processed with PBF-LB or may not perform similarly enough to their wrought counterparts. Wide adoption of AM for high temperature structural applications is also restricted, in part, by creep testing and validation. The objective of this project was to assess the creep performance of Haynes 230, a solid solution and carbide precipitate strengthened Ni-based alloy, and compositionally modified forms of the alloy that are crack-free, at 760 °C. The creep life of the modified PBF-LB Haynes 230 is higher than standard PBF-LB Haynes 230 primarily due to increased creep strength resulting from a higher fraction of intragranular carbides. As a result, the creep performance of the modified PFB-LB Haynes 230 is comparable to wrought forms of the alloy. Stress relaxation testing was also explored as a method for high-throughput creep evaluation. It was found that the minimum creep rates determined from stress relaxation testing match well with those derived from conventional creep tests on both standard and modified PBF-LB Haynes 230. It is therefore possible to use stress relaxation testing to more rapidly evaluate creep properties and even as a quality control tool for PBF-LB Ni-based alloys. The findings from these studies suggest that alloys which are considered “unprintable” can be adopted into PBF-LB AM through minor composition and/or microstructure modifications and perform similarly to wrought material. It is also evident that creep data of such materials can be acquired more rapidly with high throughput creep testing. With the implementation of these strategies, there is potential for the development of new alloys and manufacturing methods to be hastened and for the advancement of cleaner energy production.
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