Abstract
This study demonstrates metal fused filament fabrication (MF3) as an alternative additive and highly flexible manufacturing method for free-form fabrication of high-performance alloys. This novel processing, which is similar to Metal injection molding (MIM), enables a significant reduction in manufacturing costs for complex geometries, since expensive machining can be avoided. Utilizing existing equipment and reducing material expense, MF3 can pave the way for new and low-cost applications of IN 718, which were previously limited by high manufacturing costs. Iterative process optimization is used to find the most suitable MF3 process parameters. High relative density above 97% after pressureless sintering can be achieved if temperature profiles and atmospheres are well adjusted for thermal debinding and sintering. In this study, the influence of processing parameters on the resulting microstructure of MF3 IN 718 is investigated. Samples sintered in vacuum show coarse-grained microstructure with an area fraction of 0.36% NbC at grain boundaries. Morphology and composition of formed precipitates are analyzed using transmission electron microscopy and atom probe tomography. The γ/γ″/γ′ phases’ characteristics for IN 718 were identified. Conventional heat treatment is applied for further tailoring of mechanical properties like hardness, toughness and creep behavior. Fabricated samples achieve mechanical properties similar to MIM IN 718 presented in literature.Graphical abstract
Highlights
Nickel-base superalloys are widely applied in the aerospace and automotive industry due to their excellent mechanical properties and good corrosion resistance at high temperatures [1]
This study demonstrates metal fused filament fabrication (MF3) as an alternative additive and highly flexible manufacturing method for free-form fabrication of high-performance alloys
Sidambe et al demonstrated that an optimized Metal injection molding (MIM) process can achieve elongations that fulfill the requirements of AMS 5917 [5, 9]
Summary
Nickel-base superalloys are widely applied in the aerospace and automotive industry due to their excellent mechanical properties and good corrosion resistance at high temperatures [1]. The applied heat treatment consists of solution annealing followed by aging [6], which is adopted from existing cast and wrought material specifications. After heat treatment of sintered MIM IN 718, yield and tensile strength are increased and similar to cast material [7]. Sidambe et al demonstrated that an optimized MIM process can achieve elongations that fulfill the requirements of AMS 5917 [5, 9]. In this case, the HIP step can be eliminated for further cost reduction
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