Insight to agglomeration and chemical reactions of CoAl2O4 inoculants in IN718 processed by selective laser melting

Abstract

The investigation aims to clarify the influence of scan parameters on the morphology and phase constitution of CoAl2O4 inoculants in Inconel 718 (IN718) superalloy processed by selective laser melting (SLM). Gas atomized IN718 powder feedstock was uniformly blended with 0.2 wt% of CoAl2O4 flakes and processed with a range of laser scan parameters to understand the effect of the inoculant additions on microstructure. Similar to the reactions observed in investment cast Ni-superalloys, the CoAl2O4 particles were found to chemically react with elemental Al, Cr, and Ti present in the melt pool of IN718 and become reduced into Al2O3, Cr2O3, and TiO2 oxides after the SLM process. Analyses of single melt pool beads revealed the existence of Co-rich metallic particles distributed along the surface of the oxides. However, since SLM processing involves remelting of the previously deposited layers to minimize the occurrence of porosity, this results in the dissolution of the Co-rich metallic particles that form when the CoAl2O4 particles are reduced in the melt pool. As such, the ability of the metallic Co particles to contribute to grain refinement becomes limited during SLM processing. Furthermore, the inoculant particles were found to agglomerate along the scan direction. The underlying mechanisms can be attributed to the Marangoni convection following the moving center of laser beam. It was found that decreasing energy density and increasing scan speed can effectively reduce the size and number density of the agglomerated oxide particles. Faster laser scan velocities lead to reduced convective flow within the melt pool and reduce the tendency for agglomeration. However, the reduced magnitude of energy input limited the time over which the CoAl2O4 particles could react with the melt pool. This led to the formation of lack of fusion defects and incomplete chemical reaction between CoAl2O4 and IN718 after the SLM process. The effectiveness of CoAl2O4 inoculant particles on grain refinement in as-built SLM IN718 microstructures is strongly dependent on the melt pool physics and laser scan conditions.