Investigation of microstructure and thermal expansion behaviour of a functionally graded YSZ/IN718 composite produced by laser-powder bed fusion

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Yttria-stabilized zirconia (YSZ) has been extensively used as a thermal barrier coating (TBC) for high-temperature alloys. In this research, the microstructural attributes and thermal expansion behavior of an additively manufactured functionally graded composite (YSZ/IN718 FGC) were investigated. First, a powder mixture of IN718 and YSZ (ranging from 1 wt% to 4 wt%) was achieved via low-energy ball-milling at 100 rpm. Differential scanning calorimetry (DSC) analysis depicted the melting behaviour of the powder mixtures of different YSZ content. The endothermic peaks in the DSC curve, at ∼1360 ℃, suggested that the energy needed to melt the powder mixture increases with increasing YSZ content. These varying powder compositions were used to fabricate FGC samples using L-PBF. The study investigated the effects of laser power variation along the YSZ gradient, successfully mitigating the fusion defects that had been initially observed in FGC samples. Microscopic analyses, comprising scanning electron microscopy (SEM) and transmission electron microscopy (TEM), depicted the elemental segregation of Nb and Mo at the solidification subgrain boundaries (SSBs). Furthermore, the electron backscattered diffraction (EBSD) results demonstrated the refinement of grains and a reduction in textural intensity, particularly along the YSZ gradient. Energy dispersive spectroscopy (EDS) and electron probe micro analysis (EPMA) were used to validate the uniform dispersion of YSZ particles throughout the composite matrix, with the EPMA line scan affirming a predominantly linear YSZ content variation. Lastly, the coefficients of thermal expansion (CTEs) were evaluated, both parallel and perpendicular to the build direction. A decrease of approximately ∼6 % in CTE was noted along the building or gradation direction. Notably, perpendicular to the building direction, the CTE values for specimens containing 4 wt% and 2 wt% YSZ witnessed significant reductions of ∼32 % and ∼12 %, respectively. This research significantly contributes to the understanding of the microstructural intricacies and thermal behavior of YSZ/IN718 FGC produced by L-PBF process.