Creep Analysis and Microstructural Evaluation of a Novel Additively Manufactured Nickel-Base Superalloy (ABD®-900AM)

Abstract

Abstract Nickel-base superalloys containing 30 to 50% gamma prime (γ′) volume fraction are typically used in hot section components (e.g. guide vanes or blades) for power generating gas turbines, and suitable time dependent properties are required for long-term elevated temperature operation. Additive manufacturing (AM) has recently been used to develop complex hot-section parts utilizing innovative designs with enhanced cooling features which improve efficiencies by reducing cooling air consumption. To further explore the opportunity to improve time-dependent AM superalloys, this paper focuses on a fundamental creep study and characterization of a novel nickel-base superalloy (ABD®-900AM) that was manufactured using a laser-based powder bed fusion AM process. The material was subjected to a sub-solvus solution anneal and multi-step aging heat-treatment to produce a bi-modal distribution with ∼35% volume fraction of gamma prime without post-processing hot isostatic pressing (HIP). Microstructural characterization was carried out for the as-built and fully heat-treated structures, and a creep-rupture test program was conducted to study the resultant creep properties. Activation energies and stress exponents in addition to rupture strength and deformation resistance, were compared to traditionally cast IN939 and IN738 materials. After testing, specimens were evaluated using a variety of microscopy tools to determine location and features associated with creep damage. The optimized chemistry for ABD®-900AM was printed crack free and fully dense in contrast to studies on similar alloys where significant process development and post-build heat-treatments were required. High-temperature mechanical properties in the heat-treated material showed some decrease in creep strength when compared to traditional casting. This strength and rupture life debit was dependent on build orientation, but a considerable increase in creep ductility was observed due to differences in the microstructure when compared with similar AM alloys. Analysis of creep data showed differences in creep mechanisms compared to traditional cast alloys. The relationship between microstructure and creep mechanisms is discussed, and ongoing work to further improve rupture strength through heat-treatment optimization will be highlighted.