Abstract
The realisation of employing Additive Layer Manufacturing (ALM) technologies to produce components in the aerospace industry is significantly increasing. This can be attributed to their ability to offer the near-net shape fabrication of fully dense components with a high potential for geometrical optimisation, all of which contribute to subsequent reductions in material wastage and component weight. However, the influence of this manufacturing route on the properties of aerospace alloys must first be fully understood before being actively applied in-service. Specimens from the nickel superalloy C263 have been manufactured using Powder Bed Direct Laser Deposition (PB-DLD), each with unique post-processing conditions. These variables include two build orientations, vertical and horizontal, and two different heat treatments. The effects of build orientation and post-process heat treatments on the materials’ mechanical properties have been assessed with the Small Punch Tensile (SPT) test technique, a practical test method given the limited availability of PB-DLD consolidated material. SPT testing was also conducted on a cast C263 variant to compare with PB-DLD derivatives. At both room and elevated temperature conditions, differences in mechanical performances arose between each material variant. This was found to be instigated by microstructural variations exposed through microscopic and Energy Dispersive X-ray Spectroscopy (EDS) analysis. SPT results were also compared with available uniaxial tensile data in terms of SPT peak and yield load against uniaxial ultimate tensile and yield strength.
Highlights
With the ever-changing performance and environmental demands within the aerospace industry, there is a necessity for more advanced manufacturing methods to be employed
A fine, regular dispersion coupled with larger blocky types of what is thought to be M6 C and MC carbides can be found within intergranular regions within the cast material variant, a feature not present within the Powder Bed Direct Laser Deposition (PB-DLD) microstructures
Cast C263 to rank the mechanical performance at both room temperature and 780 ◦ C
Summary
With the ever-changing performance and environmental demands within the aerospace industry, there is a necessity for more advanced manufacturing methods to be employed. ALM is a process that involves the net-shape fabrication of a three-dimensional structure by fusing powders with a high-energy heat source on a layer-by-layer basis [1,2]. This method offers the ability to improve the buy-to-fly ratio by minimising material wastage through reduced need for subtractive machining and improvements to achievable geometries [3]. These advantages over conventional processing routes are attractive to the aerospace industry, with the requirement for weight savings and improved fuel consumptions. As well as creating the scope for significant weight reductions, a CAD driven system combined with small laser diameters [4] provides the capability of Materials 2017, 10, 457; doi:10.3390/ma10050457 www.mdpi.com/journal/materials
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