Knowledge of Process-Structure-Property Relationships to Engineer Better Heat Treatments for Laser Powder Bed Fusion Additive Manufactured Inconel 718

TL;DR

This study investigates the microstructural effects of various heat treatments on laser powder bed fusion Inconel 718, developing an optimized heat treatment that enhances mechanical properties over standard methods.

Contribution

It introduces a novel heat treatment process tailored for additive manufacturing Inconel 718, improving its microstructure and mechanical performance compared to conventional treatments.

Findings

Optimized heat treatment eliminates Laves and delta phases.

Enhanced microstructure stabilizes dislocation cells and precipitates dense nanoparticle populations.

Significant increases in strength and ductility over industry standard treatments.

Abstract

Dislocation structures, chemical segregation, {\gamma ^{\prime}, {\gamma ^{\prime \prime}}, {\delta} precipitates and Laves phase were quantified within the microstructures of Inconel 718 (IN718) produced by laser powder bed fusion additive manufacturing (AM) and subjected to standard, direct aging, and modified multi-step heat treatments. Additionally, heat-treated samples still attached to the build plates vs. those removed were also documented for a standard heat treatment. The effects of the different resulting microstructures on room temperature strengths and elongations to failure is revealed. Knowledge derived from these process structure property relationships was used to engineer a super solvus solution anneal at 1020 degC for 15 minutes, followed by aging at 720 degC for 24 hours heat treatment for AM-IN718 that eliminates Laves and {\delta} phases, preserves AM specific dislocation cells that are shown to be stabilized by MC carbide particles, and precipitates dense {\gamma ^{\prime} and {\gamma ^{\prime \prime}} nanoparticle populations. This 'optimized for AM-IN718 heat treatment' results in superior properties relative to wrought/additively manufactured, then industry standard heat treated IN718: relative increases of 7/10 percent in yield strength, 2/7 percent in ultimate strength, and 23/57 percent in elongation to failure are realized, respectively, regardless of as-built vs. machined surface finishes.