A New Class of Alumina-Forming Superalloy for 3D Printing

TL;DR

This paper introduces a novel alumina-forming superalloy optimized for 3D printing, demonstrating improved crack resistance, high-temperature strength, and oxidation resistance compared to traditional alloys, with specific processing and heat treatment strategies.

Contribution

The study presents a new crack-resistant nickel-based superalloy suitable for laser powder bed fusion, with optimized alloy composition and heat treatment to enhance mechanical and oxidation properties.

Findings

Superalloy shows high tensile strength up to 900°C.

Oxidation resistance is superior with high Al content.

Cracking is avoided in the new alloy, unlike CM247LC.

Abstract

A new class of crack-resistant nickel-based superalloy containing high $\gamma^\prime$ fraction is studied for the laser-powder bed fusion (L-PBF) process. The effects of the (Nb+Ta)/Al ratio is emphasised, a strategy that is shown to confer excellent low-temperature strength whilst maintaining oxidation resistance at high temperatures via stable alumina scale formation. The processability of the new alloys is characterised with respect to defect assessment by micro-focus x-ray computed tomography; use is made of a prototype turbine blade geometry and the heritage alloy CM247LC as a benchmark. In all cases, some processing-related porosity is present in thin wall sections such as the trailing edge, but this can be avoided by judicious processing. The cracking seen in CM247LC -- in solid-state, liquation and solidification forms -- is avoided. A novel sub-solvus heat treatment strategy is proposed which takes advantage of AM not requiring solutioning; super-solvus heat treatment is inappropriate since it embrittles the material by deterioration of the texture and coarsening of grain boundary carbides. The tensile strength of the new superalloy is greatest when the Nb+Ta content is highest and exceeds that of CM247LC up to $\sim$900$\,$$^\circ$C. The oxidation resistance is best when Al content is highest, and oxidation-assisted cracking resistance maximized when the (Nb+Ta)/Al ratio is balanced. In all cases these are equivalent or superior to that of CM247LC. Nevertheless, the creep resistance of the new alloys is somewhat inferior to that of CM247LC for which the $\gamma^\prime$, C, and B contents are higher; this implies a processing/property trade-off which requires further clarification.