On the role of the preheat temperature in electron-beam powder bed fusion processed IN718

Process parameters optimization in additive manufacturing (AM) is usually required to unlock superior properties, and this is often facilitated by modeling. In electron beam powder bed fusion (E-PBF), the preheat temperature is an important parameter to be optimized as it significantly influences the microstructure and properties. Here we compare the effect of two preheat temperatures (1000 and 950°C, above and below δ-phase solvus temperature) on the microstructural evolution of E-PBF IN718 Ni-based superalloy. Using thermal and thermo-kinetic modeling, we predict microstructural changes and compare them with experimental findings. A decrease of only 50°C in the preheat temperature has a low impact on the solidification microstructure with a slight reduction in columnar grain width. In the solid-state, higher preheating causes intergranular δ-phase precipitation, contributing to a higher γ" precipitation potential, formation of co-precipitates, and higher hardness. The lower preheat temperature induces intergranular and intragranular δ-phase precipitation, reducing the γ" precipitation potential and hardness. The chemical composition of γ' and γ" is largely unaffected by the preheat temperature variation. These insights underscore the importance of preheat temperature optimization in microstructure design and property control during E-PBF

Discontinuous γ′ nucleation due to Boron and Carbon segregation in Ni-based superalloys

Discontinuous γ′ precipitation is a solid-state phase transformation that involves nucleation at migrating grain boundaries during slow cooling, resulting in rod-like γ’. It has recently found applications in addressing hot-working challenges in Ni-based superalloys and large-scale nanorod production. However, more widespread adoption of discontinuous precipitation requires a better understanding of its nucleation and growth stages. Existing research provides inconclusive results on whether elemental segregation or secondary phases serve as nucleation sites. The nucleation mechanisms at these sites remain unclear due to two key factors. Firstly, elemental segregation reduces grain boundary energy, consequently decreasing the driving force for heterogeneous nucleation. Secondly, the growth of discontinuous γ′ is directly linked to grain boundary mobility, which is reduced by solute drag or Zener pinning. Here, we compare two Ni-based superalloys with different B and C contents to establish their role in discontinuous γ′ precipitation. We show that the high B & C variant exhibits increased susceptibility to discontinuous γ′ nucleation compared to the low B & C variant. In the high B & C variant only, discontinuous γ′ precipitation is achieved at a cooling rate of 5 °C/min. At a slower cooling rate of 1 °C/min, both variants undergo an almost complete transformation via the discontinuous reaction. Atom probe microscopy confirms that nucleation occurs at grain boundaries with increased interfacial excess of B and C, rather than at carbides or borides. CALPHAD simulations show that elevated B and C concentrations around grain boundaries locally increase the general driving force for γ′ nucleation. As growth proceeds, the morphology transitions from initial fan-like into spaghetti-like structures, alongside with emergence of misfit dislocations where differently aligned discontinuous γ′ cells intersect. We suggest that stresses cells exert on each other determine growth directions, leading to the spaghetti morphology. These insights are pivotal for controlling discontinuous precipitation and facilitating broader adoptions in advanced hot-working and nanotechnology

Grain boundary network evolution in electron-beam powder bed fusion nickel-based superalloy Inconel 738

Additive manufacturing (AM) of alloys has attracted much attention in recent years for making geometrically complex engineering parts owing to its unique benefits, such as high flexibility and low waste. The in-service performance of AM parts is dependent on the microstructures and grain boundary networks formed during AM, which are often significantly different from their wrought counterparts. Characteristics such as grain size and morphology, texture, and the detailed grain boundary network are known to control various mechanical and corrosion properties. Advanced understanding on how AM parameters affect the formation of these microstructural characteristics is hence critical for optimising processing parameters to unlock superior properties. In this study, the difficult-to-weld nickel-based superalloy Inconel 738 was fabricated via electron-beam powder bed fusion (EPBF) following linear and random scanning strategies. Random scanning resulted in finer, less elongated, and crystallographically more random grains compared to the linear strategy. However, both scanning strategies achieve unique high grain structure stability up to 1250 ℃ due to the presence of carbides pinning the grain boundaries. Despite significant difference in texture and morphology, majority of grains terminated on {100} habit planes in both linear and random built samples. The results show potential for controlling grain boundary networks during EPBF by tuning scan strategies

Interphase boundary segregation in IN738 manufactured via electron-beam powder bed fusion

Electron-beam powder bed fusion (EPBF) has been demonstrated to enable crack-free additive manufacturing of the traditionally non-weldable IN738 Ni-based superalloy. This is related to grain boundary (GB) segregation and precipitation phenomena during EPBF thermal cycling. We investigate such GB microstructures around typical interphase boundaries in IN738. Cyclic reheating results in γʹ dissolution, reprecipitation, and formation of layers enriched in refractory elements at γʹ-γʹ interfaces. Interfacial excess shows that >10 atomic layers of Cr and 3.5 of Co at the GB suppress the segregation of W, B, and C. GBs around heterogeneously nucleated γ grains are decorated with less Cr and Co. This is linked to microsegregation of carbide and boride-forming elements, facilitating diffusion of minor elements during cooling. A heterogeneous interfacial excess profile at a γʹ-γʹ interface is reported. These findings improve the current understanding of interphase boundaries and segregation in EPBF-manufactured IN738, possibly contributing to crack-free additive manufacturing

Precipitation-controlled grain boundary engineering in a cast & wrought Ni-based superalloy

Grain boundary engineering (GBE) describes the various approaches to control the fraction and composition of special boundaries in designing engineering materials. For example, complex thermo-mechanical processing routes are harnessed to increase the fraction of Σ3 twin boundaries, bringing about improvements to strength, toughness, and corrosion properties in austenitic stainless steels. However, high-temperature gas turbine engine components designed for the most demanding applications must be manufactured from Ni-based superalloys. To provide the required high-temperature strength, their microstructures are highly complex and consist of an austenitic γ-matrix, γ' precipitates, and grain boundary (GB) carbides, and/or borides. GBE approaches for Ni-based superalloys have been reported to reduce in-service GB cracking via targeted engineering of the GB microstructure. However, the same complex microstructures severely limit the processability of the most advanced Ni-based superalloys required to develop the next generation gas turbine engines. To tackle this challenge, we propose precipitation-controlled GBE for Ni-based superalloys with limited formability, via formation of GB serrations and precipitation upon slow cooling. We showcase our approach by achieving controlled GB precipitation of GB-γ' and M6C carbides in the cast & wrought Ni-based superalloy René 41 via a simple heat treatment. Ductility improvements are predicted via crystal plasticity modeling due to increased slip transmission compatibility. Instead of generating additional Σ3 twin boundaries only, these interfaces are directly incorporated into the GB network. It is shown that precipitation-controlled GBE is enabled by GB-γ' nucleating heterogeneously on M6C whereby competitive coarsening of GB-γ' provides the driving force. The fundamental mechanisms of our GBE approach are discussed and summarized in a qualitative microstructural model

GermOnline 4.0 is a genomics gateway for germline development, meiosis and the mitotic cell cycle

GermOnline 4.0 is a cross-species database portal focusing on high-throughput expression data relevant for germline development, the meiotic cell cycle and mitosis in healthy versus malignant cells. It is thus a source of information for life scientists as well as clinicians who are interested in gene expression and regulatory networks. The GermOnline gateway provides unlimited access to information produced with high-density oligonucleotide microarrays (3′-UTR GeneChips), genome-wide protein–DNA binding assays and protein–protein interaction studies in the context of Ensembl genome annotation. Samples used to produce high-throughput expression data and to carry out genome-wide in vivo DNA binding assays are annotated via the MIAME-compliant Multiomics Information Management and Annotation System (MIMAS 3.0). Furthermore, the Saccharomyces Genomics Viewer (SGV) was developed and integrated into the gateway. SGV is a visualization tool that outputs genome annotation and DNA-strand specific expression data produced with high-density oligonucleotide tiling microarrays (Sc_tlg GeneChips) which cover the complete budding yeast genome on both DNA strands. It facilitates the interpretation of expression levels and transcript structures determined for various cell types cultured under different growth and differentiation conditions

Improved Thermodynamic Descriptions of Carbides in Ni-Based Superalloys

The Ni-based superalloy René 41 has sparked recent interest for applications in next-generation aircraft engines due to its high-temperature strength that is superior to all similar grades. These desirable properties are achieved by careful control of the microstructure evolution during thermomechanical processing, and this is commonly informed by simulations. In particular, the grain boundary carbides M6C and M23C6 play an essential role in controlling the grain size and strength of the final product. Therefore, a solid understanding of the thermodynamic stability and thermokinetic evolution of these carbides is essential. However, thermokinetic simulations using existing thermodynamic databases have been demonstrated to have discrepancies between thermodynamic stabilities and experimental observations. Here, we collected a new experimental time–temperature–precipitation diagram. In conjunction with improved crystallographic descriptions, these experimental results are used to modify a CALPHAD database for M6C and M23C6. The modified database correctly identifies temperature regions with rapid carbide precipitation kinetics. Further, kinetic simulations and strengthening models successfully predict the hardness increase due to γ′ precipitation. The modified database has been applied to Udimet 700, Waspaloy, and Haynes 282, demonstrating improved results. These updates will facilitate more accurate simulations of the microstructure evolution during thermomechanical processing of advanced Ni-based superalloys for aerospace and other applications

Thermomechanical and Microstructural Analysis of the Influence of B- and Ti-Content on the Hot Ductility Behavior of Microalloyed Steels

The effects of the combined addition of B and Ti, as well as the influence of different strain rates on the hot ductility behavior of low carbon, continuously cast, microalloyed steels were investigated in this work. Tensile tests, microstructure analyses, and thermokinetic simulations were performed with in situ melted samples. Furthermore, prior austenite grain evaluations were carried out for the two different microalloyed steels. Increasing the strain rate brought improvements to the ductility, which was more significant in the steel with the leanest composition. The steel containing more B and Ti presented a better hot ductility behavior under all conditions tested. The main causes for the improvements rely on the precipitation behavior and the austenite–ferrite phase transformation. The preferential formation of TiN instead of fine BN and AlN was seen to be beneficial to the ductility, as well as the absence of MnS. Grain boundary segregation of free B that did not form BN retarded the ferrite formation, avoiding the brittleness brought by the thin ferrite films at the austenite grain boundaries. Furthermore, it was revealed that for the steels in question, the prior austenite grains have less influence on the hot ductility behavior than the precipitates and ferrite formation

Grain boundary crystallography and segregation in Ni-based superalloy INC738 manufactured by electron-beam powder bed fusion in as-built and annealed conditions

The excellent high-temperature properties of Ni-based superalloy INC738 are due to its hierarchical microstructure, making it an ideal engineering material for high-temperature applications. Engineering parts are now increasingly made via electron beam powder bed fusion (EPBF), an additive manufacturing technique suitable for such hard-to-weld Ni-based superalloys, due to lower thermal gradients and unmatched scan path control. The thermal cycles induced by EPBF impact characteristics of the γ-matrix, γ’ precipitates, secondary phases such as carbides, grain boundary (GB) solute segregation and, in turn, properties including GB cohesion and strength. However, a more thorough understanding of the GB microstructure evolution with focus on GB chemistry and character is required to optimise properties. We systematically investigate texture, grain structure, GB habit planes, and GB segregation in INC738 fabricated with linear versus random EPBF scanning strategies. We show that random scanning is a suitable strategy to inhibit cracking, refine grains, and decrease segregation of Cr, Mo, C, and B at GBs. For both scanning strategies, γ/γ GBs predominantly terminate on {100} planes and are decorated with C, B, Mo, and W. Upon 2 h annealing at 1180 °C and 1250 °C, the GB character and texture are shown to remain stable despite a reduction in GB interfacial excess. After 24 h annealing at 1250 °C, GB segregation and depletion are nearly eradicated, while static recrystallisation is observed with a predominant formation of annealing twins and GBs terminating on {111} planes. These findings are critical for defect-free additive manufacturing of INC738 and similar grades for superior high-temperature performance