Abstract
Many inherent issues, such as the detrimental residual stress, columnar grains with anisotropy, and weak mechanical properties, have severely impeded the adoption of metal additive manufacturing (AM) techniques including powder bed fusion and directed energy deposition (DED) processes. In this study, a hybrid AM process that consists of layer-wise laser metal deposition (i.e., a DED process) and in-situ ultrasonic impact peening (UIP) was applied to obtain Inconel 718 superalloy workpieces. Also, for further property enhancement, a post-heat treatment was applied to the deposited material obtained by the hybrid AM process. Scanning electron microscopy and transmission electron microscope were used to investigate the microstructure morphology and reveal the underlying strengthening mechanism. Electron backscatter diffraction was employed to quantitatively study the microstructure resulted from the hybrid AM process and the post-heat treatment. The profile of residual stress along the depth direction was obtained through X-ray diffraction. The results demonstrate that this hybrid AM process is capable of producing high-quality metal parts with significantly refined microstructure, and beneficial compressive residual stress along the depth into surface. Severe plastic strains are introduced by UIP, and the resulted mechanical twinning and dynamic recrystallization play an important role in refining microstructure. The material microstructure is further refined down to 100 µm, and the texture anisotropy is significantly diminished after solution treatment at 980 °C for 1 hour. Under the as-built condition, in-situ ultrasonic peening alters the residual stress component from a tensile state to an overall compressive state with a maximum value of − 190 MPa within the range of measurement depth.
Similar content being viewed by others
References
W. E. Frazier: Journal of Materials Engineering and Performance, 2014, Vol. 23, PP. 1917–1928.
J. J. Lewandowski, and M. Seifi: Annual Review of Materials Research, 2016, Vol. 46, PP. 151–186.
D.M. Jacobson and G. Bennett: in Solid Freeform Fabrication Symposium, Austin, TX, Aug, 2006, 2006, pp. 14–16.
G. Strano, L. Hao, R. M. Everson, and K. E. Evans: Journal of Materials Processing Technology, 2013, Vol. 213, PP. 589–597.
P. Mercelis, and J.-P. Kruth: Rapid Prototyping Journal, 2006, Vol. 12, PP. 254–265.
G. P. Dinda, A. K. Dasgupta, and J. Mazumder: Materials Science and Engineering: A, 2009, Vol. 509, PP. 98–104.
H. Qi, M. Azer, and A. Ritter: Metallurgical and Materials Transactions A, 2009, Vol. 40, PP. 2410–2422.
D. H. Smith, J. Bicknell, L. Jorgensen, B. M. Patterson, N. L. Cordes, I. Tsukrov, and M. Knezevic: Materials Characterization, 2016, Vol. 113, PP. 1–9.
C. Sanz, and V. G. Navas: Journal of Materials Processing Technology, 2013, Vol. 213, PP. 2126–2136.
B. AlMangour, and J.-M. Yang: Materials & Design, 2016, Vol. 110, PP. 914–924.
B. AlMangour, and J.-M. Yang: JOM, 2017, Vol. 69, PP. 2309–2313.
N. E. Uzan, S. Ramati, R. Shneck, N. Frage, and O. Yeheskel: Additive Manufacturing, 2018, Vol. 21, PP. 458–464.
W. Guo, R. Sun, B. Song, Y. Zhu, F. Li, Z. Che, B. Li, C. Guo, L. Liu, and P. Peng: Surface and Coatings Technology, 2018, Vol. 349, PP. 503–510.
S. Shiva, I.A. Palani, C.P. Paul, and B. Singh: Application of Lasers in Manufacturing, Springer, Berlin, 2019, pp. 1–20.
J. Donoghue, A. A. Antonysamy, F. Martina, P. A. Colegrove, S. W. Williams, and P. B. Prangnell: Materials Characterization, 2016, Vol. 114, PP. 103–114.
W. Zhao, G. C. Zha, M. Z. Xi, and S. Y. Gao: Journal of Materials Engineering and Performance, 2018, Vol. 27, PP. 1746–1752.
N. Kalentics, E. Boillat, P. Peyre, C. Gorny, C. Kenel, C. Leinenbach, J. Jhabvala, and R. E. Logé: Materials & Design, 2017, Vol. 130, PP. 350–356.
M. Zhang, C. Liu, X. Shi, X. Chen, C. Chen, J. Zuo, J. Lu, and S. Ma: Appl. Sci., 2016, vol. 6 (11), art. no. 304, https://doi.org/10.3390/app6110304.
J. Gale, and A. Achuhan: Rapid Prototyping Journal, 2017, Vol. 23, PP. 1185–1194.
G. Çam, and M. Koçak: International Materials Reviews, 1998, Vol. 43, PP. 1–44.
C. Slama, C. Servant, and G. Cizeron: Journal of Materials Research, 1997, Vol. 12, PP. 2298–2316.
P. L. Blackwell: Journal of Materials Processing Technology, 2005, Vol. 170, PP. 240–246.
A. Thomas, M. El-Wahabi, J. M. Cabrera, and J. M. Prado: Journal of Materials Processing Technology, 2006, Vol. 177, PP. 469–472.
J. J. Schirra, R. H. Caless, and R. W. Hatala: Superalloys, 1991, Vol. 718, PP. 375–388.
P. K. Gokuldoss, S. Kolla, and J. Eckert: Materials, 2017, vol. 10 (6), art. no. 672, https://doi.org/10.3390/ma10060672.
S. Prabhakaran, A. Kulkarni, G. Vasanth, S. Kalainathan, P. Shukla, and V. K. Vasudevan: Applied Surface Science, 2018, Vol. 428, PP. 17–30.
J. Z. Lu, K. Y. Luo, Y. K. Zhang, G. F. Sun, Y. Y. Gu, J. Z. Zhou, X. D. Ren, X. C. Zhang, L. F. Zhang, and K. M. Chen: Acta Materialia, 2010, Vol. 58, PP. 5354–5362.
H. W. Zhang, Z. K. Hei, G. Liu, J. Lu, and K. Lu: Acta Materialia, 2003, Vol. 51, PP. 1871–1881.
M. Wang, R. Xin, B. Wang, and Q. Liu: Materials Science and Engineering: A, 2011, Vol. 528, PP. 2941–2951.
X. Wang, E. Brünger, and G. Gottstein: Scripta Materialia, 2002, Vol. 46, PP. 875–880.
R. P. Singh, J. M. Hyzak, T. E. Howson, and R. R. Biederman: Superalloys, 1991, Vol. 718, PP. 205–215.
Y. Jin, M. Bernacki, A. Agnoli, B. Lin, G. Rohrer, A. Rollett, and N. Bozzolo: Metals, 2016, vol. 6 (1), art. no. 5, https://doi.org/10.3390/met6010005.
J. F. Radavich: in Conference proceedings on superalloy, 1989, 1989, vol. 718, pp. 229–40.
Z. Zhang, Y. Feng, Q. Tan, J. Zou, J. Li, X. Zhou, G. Sun, and Y. Wang: Mater. Des., 2019, vol. 166, art. no. 107603, https://doi.org/10.1016/j.matdes.2019.107603.
Acknowledgments
The authors wish to acknowledge the funding support from the National Science Foundation (CMMI# 1563002 and 1746147).
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Manuscript submitted May 27, 2019.
Rights and permissions
About this article
Cite this article
Wang, Y., Shi, J. Microstructure and Properties of Inconel 718 Fabricated by Directed Energy Deposition with In-Situ Ultrasonic Impact Peening. Metall Mater Trans B 50, 2815–2827 (2019). https://doi.org/10.1007/s11663-019-01672-3
Received:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11663-019-01672-3