Abstract NiCrFeAl alloy was prepared by selective laser melting (SLM) using NiCrFeAl prealloy powders as raw material. The optimizing of SLM processing parameters was carried out through optical analyzing on pores. Scanning electron microscope was ultilized for microstructure characterization of the alloy, and defects were analyzed by EBSD. The mechanical properties tests were carried out on UTM 5105 electronic universal testing machine. Results show that the optimal processing parameters of NiCrFeAl alloy fabrication are as follows: laser power of 240 W, scanning speed of 1 000 mm/s, hatching spacing of 0.12 mm and layer thickness of 0.03 mm. The corresponding tensile strength and elongation are 535 MPa and 5.8% respectively. There are solid cracks distributed between adjacent grains with large misorientation, showed intergranular fracture on horizontal and vertical cross sections. The average grain size on the horizontal cross section of the alloy is 35 μm, and the low angle grain boundaries accounts for 37.0%. The average grain size on the vertical section is 56 μm, and the low angle grain boundaries accounts for 41.0%.
XU Ruifeng,GENG Zhaowen,CHEN Chao, et al. Microstructure and defects of NiCrFeAl alloy by selective laser melting[J]. Materials Science and Engineering of Powder Metallurgy, 2022, 27(6): 586-594.
[1] 郭建亭. 高温合金材料学[M]. 北京: 科学出版社, 2010, 109-111. GUO Jianting.Materials Science and Engineering for Superalloys[M]. Beijing: Science Press, 2010: 109-111. [2] MINER R V, CASTELLI M G.Hardening mechanisms in a dynamic strain aging alloy, HASTELLOY X, during isothermal and thermomechanical cyclic deformation[J]. Metallurgical Transactions A, 1992, 23(2): 551-561. [3] WANG F.Mechanical property study on rapid additive layer manufacture Hastelloy X alloy by selective laser melting technology[J]. The International Journal Advanced Manufacturing Technology, 2012, 58(5/8): 545-551. [4] MARCHESE G, BASILE G, BASSINI E, et al.Study of the microstructure and cracking mechanisms of Hastelloy X produced by laser powder bed fusion[J]. Materials, 2018, 11(1): 1-12. [5] 王馨. 渗铝涂层对Cr20Ni80电热合金抗氧化性能研究及失效分析[D]. 兰州: 兰州理工大学, 2020. WANG Xin.Study on oxidation resistance and failure analysis of Cr20Ni80 electrothermal alloy with aluminized coating[D]. Lanzhou: Lanzhou University of Technology, 2020. [6] 路超. GH4169金属粉末选区激光熔化成型工艺及性能研究[D]. 兰州: 兰州理工大学, 2017. LU Chao.Research on process and property of selective laser melting with GH4169 metal powder[D]. Lanzhou: Lanzhou University of Technology, 2017. [7] HUANG L, JIANG L, TOPPING T D, et al.In situ oxide dispersion strengthened tungsten alloys with high compressive strength and high strain-to-failure[J]. Acta Materialia, 2017, 122(1): 19-31. [8] DADÉ M, MALAPLATE J, GARNIER J, et al.Influence of microstructural parameters on the mechanical properties of oxide dispersion strengthened Fe-14Cr steels[J]. Acta Materialia, 2017, 127(1): 165-177. [9] MASSEY C P, DRYEPONDT S N, EDMONDSON P D, et al.Multiscale investigations of nanoprecipitate nucleation, growth, and coarsening in annealed low-Cr oxide dispersion strengthened FeCrAl powder[J]. Acta Materialia, 2018, 166(1): 1-17. [10] BERMAN B.3-D printing: The new industrial revolution[J]. Business Horizons, 2012, 55(2): 155-162. [11] DEBROY T, WEI H L, ZUBACK J S, et al.Additive manufacturing of metallic components-process, structure and properties[J]. Progress Materials Science, 2018, 92(1): 112-224. [12] GU D, SHI X, POPRAWE R, et al. Material-structure- performance integrated laser-metal additive manufacturing[J]. Science, 2021, 372(6545): eabg1487. [13] HERZOG D, SEYDA V, WYCISK E, et al.Additive manufacturing of metals[J]. Acta Materialia, 2016, 117(1): 371-392. [14] SANAEI N, FATEMI A.Defects in additive manufactured metals and their effect on fatigue performance: A state-of-the-art review[J]. Progress Materials Science, 2021, 117(1): 100724. [15] SVETLIZKY D, DAS M, ZHENG B, et al.Directed energy deposition (DED) additive manufacturing: Physical characteristics, defects, challenges and applications[J]. Materials Today, 2021, 49(1): 271-295. [16] ZHONG M, SUN H, LIU W, et al.Boundary liquation and interface cracking characterization in laser deposition of Inconel 738 on directionally solidified Ni-based superalloy[J]. Scripta Materialia, 2005, 53(2): 159-164. [17] GRIFFITHS S, TABASI H G, IVAS T, et al.Combining alloy and process modification for micro-crack mitigation in an additively manufactured Ni-base superalloy[J]. Additive Manufacturing, 2020, 36(1): 101443. [18] ZHOU W, ZHU G, WANG R, et al.Inhibition of cracking by grain boundary modification in a non-weldable nickel-based superalloy processed by laser powder bed fusion[J]. Materials Science Engineering A, 2020, 791(1): 139745. [19] CLOOTS M, UGGOWITZER P J, WEGENER K.Investigations on the microstructure and crack formation of IN738LC samples processed by selective laser melting using Gaussian and doughnut profiles[J]. Materials and Design, 2016, 89(1): 770-784. [20] HARRISON N J, TODD I, MUMTAZ K.Reduction of micro-cracking in nickel superalloys processed by Selective Laser Melting: A fundamental alloy design approach[J]. Acta Materialia, 2015, 94(1): 59-68. [21] BIDRON G, DOGHRI A, MALOT T, et al.Reduction of the hot cracking sensitivity of CM-247LC superalloy processed by laser cladding using induction preheating[J]. Journal of Materials Processing Technology, 2019, 277(1): 116461. [22] TANG Y T, PANWISAWAS C, GHOUSSOUB J N, et al.Alloys-By-Design: Application to New Superalloys for Additive Manufacturing[J]. Acta Materialia, 2020, 202(1): 417-436. [23] HAN Q Q, GUYC, SETCHIR, et al.Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy[J]. Additive Manufacturing, 30(1): 1-11. [24] TOMUS D, ROMETSCH P A, HEILMAIER M, et al.Effect of minor alloying elements on crack-formation characteristics of Hastelloy-X manufactured by selective laser melting[J]. Additive Manufacturing, 2017, 16(1): 65-72. [25] KOUS. A criterion for cracking during solidification[J]. Acta Materialia, 2015, 88(1): 366-374. [26] CONIGLIO N, CROSS C E.Initiation and growth mechanisms for weld solidification cracking[J]. International Materials Reviews, 2013, 58(7): 375-397. [27] WANG N, MOKADEM S, RAPPAZ M, et al.Solidification cracking of superalloy single- and bi-crystals[J]. Acta Materialia, 2004, 52(11): 3173-3182. [28] KITANO H, TSUJII M, KUSANO M, et al.Effect of plastic strain on the solidification cracking of Hastelloy-X in the selective laser melting process[J]. Additive Manufacturing, 2021, 37(1): 101742. [29] MONTERO-SISTIAGA M L, POURBABAK S, VAN HUMBEECK J, et al. Microstructure and mechanical properties of Hastelloy X produced by HP-SLM (high power selective laser melting)[J]. Materials and Design, 2019, 165(1): 107598. [30] OJO O A, RICHARDS N L, CHATURVEDI M C.Contribution of constitutional liquation of gamma prime precipitate to weld HAZ cracking of cast Inconel 738 superalloy[J]. Scripta Materialia, 2004, 50(5): 641-646. [31] ZHANG W, LIU F, LIU F, et al.Microstructural evolution and cracking behavior of Hastelloy X superalloy fabricated by laser directed energy deposition[J]. Journal of Alloys and Compounds, 2022, 905(1): 164179. [32] CHANDRA S, TAN X, NARAYAN R L, et al.A generalised hot cracking criterion for nickel-based superalloys additively manufactured by electron beam melting[J]. Additive Manufacturing, 2020(1): 101633. [33] CHAUVET E, KONTIS P, GAULT B, et al.Hot cracking mechanism affecting a non-weldable Ni-based superalloy produced by selective electron beam melting[J]. Acta Materialia, 2017, 142(1): 82-94. [34] RONG P, WANG N, WANG L, et al.The influence of grain boundary angle on the hot cracking of single crystal superalloy DD6[J]. Journal of Alloys and Compounds, 2016, 676(1): 181-186. [35] JIAN Z, SINGER R F.Effect of grain-boundary characteristics on castability of nickel-base superalloys[J]. Metallurgical and Materials Transactions A, 2004, 35(3): 939-946. [36] ZHOU Y, VOLEK A, SINGER R F.Effect of grain boundary characteristics on hot tearing in directional solidification of superalloys[J]. Journal of Materials Research, 2006, 21(9): 2361-2370. [37] BI J, LEI Z, CHEN Y, et al.Microstructure, tensile properties and thermal stability of AlMgSiScZr alloy printed by laser powder bed fusion[J]. Journal of Materials Science and Technology, 2021, 69(1): 200-211. [38] NI M, CHEN C, WANG X, et al.Anisotropic tensile behavior of in situ precipitation strengthened Inconel 718 fabricated by additive manufacturing[J]. Materials Science and Engineering A, 2017, 701(1): 344-351. [39] YANG M, WANG L, YAN W.Phase-field modeling of grain evolutions in additive manufacturing from nucleation, growth, to coarsening[J]. Additive Manufacturing, 2021, 47(1): 102286. [40] PHAM M S, DOVGYY B, HOOPER P A, et al.The role of side-branching in microstructure development in laser powder-bed fusion[J]. Nature Communications, 11(1): 14453. [41] SONG B, DONG S, CODDET P, et al.Fabrication of NiCr alloy parts by selective laser melting: Columnar microstructure and anisotropic mechanical behavior[J]. Materials and Design, 2014, 53(1): 1-7. [42] 谭树杰, 李多生, QIN Qinghua, 等. 激光3D打印80Ni20Cr合金的显微组织及力学性能[J]. 中国有色金属学报, 2017, 27(8): 1572-1579. TAN Shujie, LI Duosheng, QIN Qinghua, et al.Microstructure and mechanical properties of 80Ni20Cr alloy manufactured by laser 3D printing technology[J]. The Chinses Journal of Nonferrous Metals, 2017, 27(8): 1572-1579.
2022, Vol. 27 
