Session: 18-05: Failure Prediction & Life Assessment II

Paper Number: 152136

Utilizing ICME Informed Inoculation to Solve Solidification Cracking and Improve Properties for Powder Bed Fusion Printed Alloy 230 

Additive Manufacturing (AM) has revolutionized the production of complex geometries for demanding structural applications. Despite its transformative potential, many AM technologies often encounter material challenges such as solidification cracking often observed in nickel-based superalloys. A notable example is Haynes Alloy 230, a solid-solution and carbide strengthened nickel based superalloy that is known for its excellent weldability with traditional arc based processes, but suffers from extensive solidification cracking in laser powder bed fusion (LPBF). In this work, we developed an integrated computational materials engineering (ICME) framework to explain the LPBF solidification cracking in this traditionally weldable alloy. We then leveraged this ICME approach together with reactive additive manufacturing (RAM) technology to develop a new Alloy 230 variant, designated as Ni230-RAM1. This innovative alloy incorporates increased nucleation sites to promote finer and more equiaxed solidification to effectively eliminate cracking and thus significantly enhance mechanical properties.

The LPBF printed Ni230-RAM1 demonstrates improvements over LPBF printed unmodified Alloy 230, with a 38% increase in yield strength (YS), a 48% increase in ultimate tensile strength (UTS), and a 176% increase in elongation (EL%) at 760°C. Furthermore, the elevated temperature tensile and low cycle fatigue performance LPBF Ni230-RAM1 is equivalent or superior to that of wrought Haynes 230. The generally superior mechanical performance compared to standard LPBF and wrought Haynes 230 is attributed to the crack free microstructure of LPBF Ni230 RAM1 combined with a finer grain size and a higher fraction of carbides. The successful development of Ni230-RAM1 marks a significant milestone in the commercialization of LPBF superalloys, offering a robust solution for high-performance, high-temperature, and high-corrosion applications where durability and precision are paramount.

Presenting Author: Benjamin Rafferty Elementum 3D

Presenting Author Biography: Benjamin Rafferty,

Elementum 3D: Material Engineer Nickel, Ferrous and Refractory Lead

B.S. in Metallurgy and Materials Engineering 2017

Authors:

Benjamin Rafferty Elementum 3D
Daniel Mcconville Colorado School of Mines
Stanley Baldwin Elementum 3D
Kevin Eckes Elementum 3D
Jeremy Iten Elementum 3D
Jonah Klemm-Toole Colorado School of Mines