An analysis of fatigue failure mechanisms in an additively manufactured and shot peened IN 718 nickel superalloy

The family of additive manufacturing techniques has been attracting significant attention of manufacturers and researchers, due to its unrivalled flexibility to fabricate and repair geometrically complex objects. However, material shaping is not sufficient: wide adoption of additive manufacturing can only occur upon the achievement of satisfactory mechanical performance in terms of structural integrity. The present study exploits a wide range of micro-scale experimental techniques to shed light on fatigue failure mechanisms of Laser Metal Deposition IN718 Ni-base superalloy, and to study the effect of shot peening treatment. Thorough microstructural and fractographic analyses revealed the main deformation mechanism associated with twinning during crack propagation, while crack initiation was found to be promoted by both slip system deformation and twinning around microstructural defects, rather than at sample free-surfaces. It was found that precipitates played a major role in determining the deformation mode. It was discovered that in this case-study, shot-peening residual stresses may have a detrimental effect, in view of the presence of the largest defects within a region where tensile residual stress was present. The results presented here improve understanding of failure mechanisms and thus define future directions of development for manufacture optimisation

Data on the occurrence of a Brass texture and elastic anisotropy in laser blown powder processed superalloy IN718.

The additive manufacturing (AM) of components through laser-blown-powder directed-energy-deposition (LBP-DED) is highly applicable to the repair of aerospace components. Fabrication of superalloys with this technique, as with other AM methods, often encounters complications that include the formation of undesired phases, irregular microstructure and texture leading to anisotropic elastic properties. Heat treatments and other post-processing techniques can be used to mitigate these issues. The collected data demonstrates the effects of different heat treatment protocols on the microstructure, elastic properties, and hardness of LBP-DED IN718. In this study eight different heat treatment were used to investigate the effects of treatment time and temperature. The microstructure was investigated through SEM, with XRD and EDX used for phase analysis. The texture was characterised using SEM coupled with EBSD and the elastic properties were determined from resonant ultrasound spectroscopy.Rolls-Royc

Effect of NbC inoculants on the elastic properties and microstructure of additively manufactured IN718

In this study, the effects of NbC inoculants on the elastic properties and microstructure of laser blown powder-directed energy deposition (LBP-DED) IN718 are investigated. The addition of the NbC particles increased the volume fraction of MC-type carbides and decreased that of the Laves phase. It was found that the inoculant containing samples exhibited a marginally increased hardness and an enhanced Brass texture component {110} . The occurrence of this textural enhancement is theorised to be a result of the NbC restricting dendritic growth along specific directions during build. The addition of the inoculant therefore offers a method of achieving a degree of microstructural and textural control during additive manufacturingNERC Grants No. NE/B505738/1 and No. NE/F017081/1 EPSRC Grant No. EP/I036079/

Data on the effect of NbC inoculants on the elastic and microstructural evolution of LBP-DED IN718.

The use of inoculants added to precursor powder is a method of influencing grain growth during fabrication. Niobium carbide (NbC) particles have been added to IN718 gas atomised powder for additive manufacturing via laser-blown-powder directed-energy-deposition (LBP-DED). The collected data in this study reveals the effects of the NbC particles on the grain structure, texture and elastic properties, and oxidative properties of LBP-DED IN718 in the As-DED and heat-treated conditions. The microstructure was investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM) coupled with electron backscattered diffraction (EBSD), and transmission electron microscopy (TEM) coupled with energy dispersive X-ray spectroscopy (EDS). Resonant ultrasound spectroscopy (RUS) was used to measure the elastic properties and phase transitions during standard heat treatments. Thermogravimetric analysis (TGA) is used to probe the oxidative properties at 650°C.The authors acknowledge funding from the Engineering and Physical Sciences Research Council, UK and from Rolls-Royce plc. RUS facilities were established through grants from the Natural Environment Research Council (Grants No. NE/B505738/1 and No. NE/F017081/1) and the Engineering and Physical Sciences Research Council (Grant No. EP/I036079/1) to MAC. The authors would like to thank Dr. H. T. Pang for his assistance in data collection