Structure and Properties Evolution of AZhK Superalloy Prepared by Laser Powder Bed Fusion Combined with Hot Isostatic Pressing and Heat Treatment

Abstract

The structure and properties of samples obtained by the laser powder bed fusion (LPBF) method from the AZhK alloy, intended for the manufacture of heavily loaded body parts with operating temperatures up to 800 °C, have been studied. The optimal mode of LPBF, ensuring the attainment of the minimal residual porosity of 0.02%, was identified for the superalloy AZhK. Additionally, the evolution of the microstructure of LPBF samples after hot isostatic pressing (HIP) and heat treatment (HT) was studied using optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The macrostructure of LPBF samples is represented by columnar grains oriented in the direction of predominant heat dissipation, perpendicular to the build plate. At the microlevel, the structure consists of colonies of columnar dendrites. Nb4AlC3 and Nb6C4 carbides, as well as the Mo2Hf Laves phase, are precipitated in the interdendritic region as a result of doping element segregation. The low strength of the LPBF samples (σ = 967 ± 10 MPa) is caused by the fact that there are no reinforcing particles and by high internal stress due to high crystallization speed. HIP and HT were found to have a favorable effect on the structure and properties of the LPBF samples. The post-treatment resulted in uniform distribution of γ′-phase precipitates sized up to 250 nm in the matrix bulk and carbides at grain boundaries, as well as Laves phase dissolution. Therefore, the strength characteristics were significantly improved: by 45% at room temperature and by 50% at elevated temperatures. High strength and ductility were attained (at 20 °C, σ20 = 1396 ± 22 MPa and δ = 19.0 ± 3.0 %; at 650 °C, σ650 = 1240 ± 25 MPa and δ = 15.8 ± 1.5%; at 750 °C, σ750 = 1085 ± 23 MPa and δ = 9.1 ± 2.3%). An ejector-type part was fabricated, and its geometric parameters coincided with those in the electronic models. After conducting computed tomography, it was found that there are no defects in the form of non-fusion and microcracks within the volume of the part; however, it was observed that the pore size is ≥20 μm.