This investigation focuses on unravelling the dominant influence of microsegregation and microstructure altered due to heat treatment cycle variation on creep rupture behaviour of additively manufactured Inconel 718 (AM-IN718). Two microstructural variants differing in the fraction of recrystallized grains while δ-phase being absent, were produced. A typical heat treatment (HT) cycle includes the stress-relieving of the as-built specimens at 980 °C, followed by solution treatment at 1080 °C (STA1080, a partially recrystallized microstructural variant) or 1150 °C (STA1150, a fully recrystallized microstructural variant), and double ageing (soaking at 720 °C for 8h and subsequent furnace cooling, followed by 8h at 620 °C and air cooling).Detailed microstructural characterization of two microstructural variants through correlative microscopy revealed a prevalent existence of Nb-rich precipitate-free zones (PFZ) in STA1080 than in STA1150. Creep characterization of the two microstructural variants in the temperature range of 625–675 °C and at 500–750 MPa demonstrated superior creep resistance in STA1150. The correlation of kinetic analysis and comprehensive post-deformation microstructural characterization suggests grain boundary cavitation as the main damage/softening mechanism and the reason for the difference in creep rupture behaviour between the two microstructural variants. The long-term exposure heat treatment methodology demonstrates that PFZs are the major influencing factor responsible for microsegregation-dependent creep rupture behaviour. Interestingly, the presence of the δ phase within PFZs appeared to retard cavity coalescence and failure during creep, despite its usual detrimental role in creep resistance.
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