Hot Isostatic Pressing Treatment Research Articles

High strength and fatigue performance achieved for L-PBF processed hybrid particle reinforced Al-Cu-Mg composite

This study highlights the successful manufacturing of a crack-free, dense, hybrid ex-situ/in-situ particle reinforced (Ti+B4C)/Al-Cu-Mg composite, fabricated by laser powder bed fusion and exhibiting exceptional mechanical performance. In its as-built (AB) state, the composite displays a unique microstructure characterized by equiaxed grains with an average grain size of 1.0 ± 0.3 μm, notable interdendritic microsegregation of Cu, Mg, Mn, and Fe, randomly distributed ex-situ added Ti and B4C particles featuring a surface interaction layer with the metal matrix, and in-situ formed reinforcing particles, such as TiB2 and TiC. After subjecting the material to hot isostatic pressing (HIP) and subsequent aging treatment, dissolution of interdendritically segregated elements occurs, and precipitation of Al2Cu, Al12Mg17, and Al-Fe-Cu-Mn phases is observed. Significantly enhanced fatigue performance is recorded, reaching to 107 cycles at 250 MPa in AB and 330 MPa in HIP state, marking a 32% improvement. The current study highlights the intricate relationship between the different microstructural features in AB and HIPed state, leading to fracture during tensile and fatigue loading conditions.

Effect of hot isostatic pressing on stress-rupture crack growth of a single-crystal nickel-based superalloy

The solution-treated second-generation single crystal (SX) superalloys underwent hot isostatic pressing (HIP) at 1316 ºC and 105 MPa for varying durations. This study investigates the effect of HIP on micropores and stress-rupture behavior under conditions of 980 ºC and 250 MPa. The results illustrate that the application of HIP treatment significantly reduces the porosity and volume of micropores, thereby increasing the rupture life of the alloys. With the disappearance of micropores, the crack initiation site shifts from the micropores to the γ/γʹ interface, resulting in reduced crack dimensions and decelerated propagation. Consequently, the smaller size of cracks in HIPed specimens slow down fracture. Nonetheless, the crack propagation pattern remains consistent: cracks expand perpendicular to the stress axis, connecting with cracks at other heights via secondary cracks along the <112> direction.

Microstructure evolution and mechanical properties of additively manufactured Ni-based GH4099 superalloy via hot isostatic pressing and heat treatment

In this study, GH4099 alloys with over 99.99 % density were produced by laser powder bed fusion (LPBF) and followed by hot isostatic pressing (HIP) and heat treatment (HT). The effects of HIP and HT on the microstructure evolution and mechanical properties of the additively manufactured GH4099 superalloy were examined systematically. The as-deposited columnar crystals were effectively transformed into equiaxed crystals via HIP and HT. During HIP, the elimination of defects and elemental segregation in the deposited samples occurs. However, uneven precipitation of the γ′ phase within grains causes the emergence of minor gaps in the γ matrix, which adversely affects mechanical properties. The microstructure resulting from HIP + solution treatment (ST) consists entirely of equiaxed recrystallized grains. The presence of twin and long-period stacking-ordered (LPSO) phases at twin boundaries strongly hinders dislocation behavior, and the remelting of precipitates and carbides greatly improves plasticity. Moreover, during the loading process at 900 °C, γ′ phase and carbides were re-precipitated, and the strain concentration was minimized during the precipitation process, resulting in the highest high-temperature strength. Conversely, in the HIP + solution and aging treatment (SAT) process, the progression of γ′ phase precipitation, condensation, annexation, and growth contributes to a reduction in strength. Coupled with an increase in the plasticity of the LPBF GH4099 alloy.

Comparison of fatigue life behavior between 4-point and uniaxial loading for L-PBF Ti–6Al–4V after HIP treatments

The present study investigated the effects of Hot Isostatic Pressing (HIP) on the fatigue performance of Laser Powder Bed Fusion (L-PBF) Ti–6Al–4V alloy under both 4-point bending and uniaxial testing. Three HIP-cycles were examined: standard, low temperature/high pressure (LTHP), and super beta. Moreover, an annealed heat treatment group was incorporated to compare against the HIP groups. The material microstructure was analyzed and compared across the heat treatments during the study, which showed the presence of α′ martensites, α+β Widmanstätten, and coarse equiaxed grains. Similarly, tensile and hardness testing were implemented to study the mechanical properties, where due to the effects of the HIP treatments, higher ductility but lower hardness values were recorded. Furthermore, fracture morphologies and stress-life (cycles-to-failure) (S–N) curves of the Ti–6Al–4V specimens concerning the fatigue behavior were analyzed. The HIP treatment groups behaved similarly during 4-point bending and uniaxial testing, with the LTHP obtaining a superior fatigue life behavior, followed by the standard and super beta HIP groups. In addition, the efficacy of HIP to reduce pores showed better results in the 4-point bending specimens, leading to few defects as fatigue initiators in contrast to the uniaxial specimens. Fractography results suggested that defects and microstructural features acting as fatigue crack initiators (FCI) govern the fracture behavior of uniaxial specimens. In contrast, only the presence of microstructural features controls the 4-point bending failure behavior.

Improved structure and enhanced properties of detonation sprayed W coating via hot isostatic pressing

Tungsten has garnered significant attention for its superior performance as a plasma-facing material in tokamak devices. However, its hardness and high ductile-to-brittle transition temperature present challenges for its application in plasma-facing components. To address these issues, this study employs the detonation spraying (DS) technique to prepare tungsten coatings on a TZM alloy substrate and further optimizes their properties through hot isostatic pressing (HIP) treatment. Advanced characterization techniques were utilized to conduct a detailed microstructural and compositional analysis of the coatings. The results indicated that the HIP treatment significantly reduced the porosity of the coatings, improving their density and overall quality. Additionally, HIP treatment led to a decrease in internal stress, a reduction in dislocations, and the grain growth within the coatings. The study also discussed how the HIP process improved the microstructure of the DS tungsten coatings through these mechanisms, thereby enhancing the coatings' thermodynamic properties. Mechanical property tests revealed that the coatings treated with HIP exhibited higher bonding strength and lower hardness, attributed to the increase in grain size and the reduction in dislocation density within the coatings. Thermal property tests demonstrated that the HIP-treated coatings possessed higher thermal diffusivity and specific heat capacity in the temperature range of 100 to 500 °C. Furthermore, the performance of the coatings under transient high heat flux conditions was significantly improved after the HIP treatment, showing better resistance to the thermal shock and cracking. These findings are of great importance for understanding the performance enhancement of DS tungsten coatings in nuclear fusion reactor applications via HIP, especially as candidate materials for the first wall of tokamak devices.

Surface reactivity during a hot isostatic pressing treatment of Ni-based superalloy René 77 specimens manufactured by laser powder bed fusion and metal inject molding

Additive manufactured alloys are generally affected by porosity. To solve this issue, Hot Isostatic Pressing (HIP) is a mandatory step. This work focuses on the reactivity of Ni-based superalloy René 77 during HIP at 1200 °C, in argon atmosphere. René 77 is chromia-forming in air at this temperature, but during HIP treatment, it formed α-Al2O3, Al-Ti mixed oxides and TiX (X= nitrogen/oxygen/carbon). The relative quantities of these phases depend on the specimen position inside the furnace, suggesting a gradient of impurity partial pressures. By combining experiments with thermodynamic calculations, this work contributes to a better understanding of HIP processes and suggests ways of improving them.

A laser powder bed fusion–based methodology for repairing damaged nickel-based turbine blades: Investigation of interfacial characteristics and hot isostatic pressing treatment

This study presents a methodology for repairing a damaged nickel-based turbine blade via laser powder bed fusion (LPBF) additive manufacturing. Specifically, the CM247LC nickel-based alloy was utilized to repair a damaged SRR99 nickel-based blade with LPBF, followed by hot isostatic pressing (HIP) post-treatment. The LPBF repair process achieved crack-free metallurgical bonding at the CM247LC/SRR99 interface with large epitaxially grown grains. Furthermore, HIP facilitated the formation of γ/γ’ phases with comparable dimensions at the interface as well as in the CM247LC and SRR99 regions through recrystallization. Additionally, the columnar grains in the LPBF-printed CM247LC region transformed into coarse equiaxed grains after HIP, accompanied by precipitation of nanoscale Hf-rich carbides. Meanwhile, microcracks in the LPBF-printed CM247LC region and shrinkage pores in the cast SRR99 region were effectively eliminated. The LPBF-printed CM247LC exhibited an 8.62% higher hardness compared to that of SRR99. The repaired samples showed an ultimate tensile strength of 791 MPa, with fracture occurring at the SRR99 side, indicating a reasonable metallurgical bonding strength at the CM247LC/SRR99 interface. The findings offer a novel alternative for the industrial application of repairing damaged nickel-based turbine blades.

New insights into the stress rupture life enhancement mechanisms of a nickel-based superalloy

In this paper, the effects of hot isostatic pressing (HIP) and heat treatment (HT) on the stress rupture properties of nickel-based superalloy K417G were investigated. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) were employed to analyze the microstructure, fracture morphology, determination of crack source and dislocation evolution after stress rupture fracture. The results indicate that, HIP specimens demonstrate a 19.5% reduction in stress rupture life compared to as-cast specimens, whereas HIP + HT specimens exhibit a 41% increase in stress rupture life, reaching a value of 63.04 h. The fracture mechanism of the samples under different heat treatment conditions is different. There are a large number of pores in the as-cast specimen, which leads to the initiation and propagation of cracks and eventually result in fracture. The pores in the HIP specimen are almost eliminated. However, the coarsening and uneven distribution of γ′ phase led to the weakening of the hindrance to dislocation movement. Additionally, the increase in elongated carbides at grain boundaries accelerates crack initiation and propagation. Under HIP and HT, the cubic γ′ phase is uniformly precipitated, which effectively hinders the movement of dislocation lines. Granular M23C6 carbides precipitate at grain boundaries, acting as pinning points to retard grain boundary sliding and crack propagation, thus improving the stress rupture life.

Microstructural effects on the rotating bending fatigue behavior of Ti–6Al–4V produced via laser powder bed fusion with novel heat treatments

The rotating bending fatigue (RBF) behavior (fully reversed, R = −1) of additively manufactured (AM) Ti–6Al–4V alloy produced via laser powder bed fusion (PBF-L) was investigated with respect to different microstructures achieved through novel heat treatments. The investigation herein seeks to elucidate the effect of microstructure by controlling variables that can affect fatigue behavior in Ti–6Al–4V, such as chemistry, porosity, and surface roughness. In order to control these variables, different hot isostatic pressing (HIP) treatments at 800 °C, 920 °C, and 1050 °C with a 920 °C temper were applied to three sets of Ti–6Al–4V cylinders that originated from the same PBF-L build, such that there were 30 tests per condition. After HIP treatment, the specimens were machined and tested. The highest runout stress was achieved after sub-β transus HIP at 800 °C for 2 h at 200 MPa of pressure. A significant drop in fatigue strength was attributed to large prior-β grains and grain boundary α resulting from super-β transus HIP treated specimens. For the sub-β transus HIP specimens, differences in fatigue strength were attributed to α lath thickness, relative dislocation density, and dislocation boundary strengthening.

The influence of hot isostatic pressing on precipitates, mechanical properties of Mg-12Gd-0.8Zn-0.4Zr (wt.%) alloy manufactured by sand casting

Microstructures and mechanical properties of Mg-12Gd-0.8Zn-0.4Zr (GZ1208K, wt.%) alloy under different treatments (as-cast: signed as nonHIP-GZ1208K, hot isostatic pressing (HIP): signed as HIP-GZ1208K) were characterized. Based on microstructure characterization, two prismatic precipitates, β′ and β1 precipitates, and one basal precipitate, γ′ precipitate, formed in both of nonHIP-GZ1208K and HIP-GZ1208K alloy. According to analysis, the area number density and the size of β′ precipitate could be adjusted through HIP treatment. The area number density of β′ precipitate increased after HIP treatment when aged at 32 h, and the size of β′ precipitate refined in both of the HIP-GZ1208K alloy aged at 8 h and 32 h. Except the influence of HIP treatment on microstructures, the ultimate tensile strength (UTS) and elongation of nonHIP-GZ1208K alloy also improved after HIP treatment. The UTS of the GZ1208K alloy aged at 8 h increased from 348 MPa (nonHIP-) to 371 MPa (HIP-) and the elongation increased from 2.6% to 4.7%. The density of the nonHIP-GZ1208K alloy increased after HIP treatment, that is to say the casting defects could be eliminated and the compactness of microstructures could be increased under the high pressure of HIP treatment.

TiAl Alloy Fabricated Using Election Beam Selective Melting: Process, Microstructure, and Tensile Performance

TiAl alloy is one of the most attractive candidates for a new generation of high-temperature structural materials and has broad application prospects in the aerospace field. As a typical intermetallic material, TiAl is inevitably difficult to process using conventional methods. Election beam selective melting (EBSM) is an effective method of addictive manufacturing to prepare TiAl alloy with a complex structure. However, the microstructure of TiAl alloy formed using EBSM often contains defects such as pores, which seriously reduces the mechanical properties of the material. In this work, the effects of EBSM and post-processing procedures on the microstructure and mechanical properties of Ti-48Al-2Cr-2Nb alloy were studied. The results show that the microstructure of Ti-48Al-2Cr-2Nb alloy formed using the EBSM process was dense and composed of equiaxed γ-phase and double-phase regions. A large number of dislocations that formed due to thermal stress were clearly observed inside the Ti-48Al-2Cr-2Nb alloy. When the EBSM process parameters were 13.5 mA, 4.0 m/s, and 40.50 J/mm3, as the current intensity increased, the Al content decreased, the content of α2 phase increased, and the microstructure of the material was coarse. The results of the tensile test fracture morphology indicate that the Ti-48Al-2Cr-2Nb alloy exhibited brittle fracture during tensile deformation, lacking the typical yield deformation of metal materials. As the energy density of the EBSM process increased, the mechanical properties of the Ti-48Al-2Cr-2Nb alloy first increased and then decreased. The samples prepared with an energy density of 34.50~40.50 J/mm3 had excellent mechanical properties, of which the maximum tensile strength and maximum elongation reached 643 MPa and 2.09%, respectively. The phase composition of the Ti-48Al-2Cr-2Nb alloy after hot isostatic pressing (HIP) treatment remained unchanged from the EBSM samples, but there was a slight difference in content. There was an increase in the amount of γ phase and a decrease in B2 phase, accompanied by the generation of a massive γ phase after HIP treatment. Moreover, the number of dislocations inside the material increased. The Ti-48Al-2Cr-2Nb alloy after HIP treatment exhibited obvious plastic deformation characteristics, with a tensile strength of 679 MPa and elongation of 2.5%. A heat treatment of 900 °C/5 h was performed on the Ti-48Al-2Cr-2Nb alloy after HIP. The dislocation density of the Ti-48Al-2Cr-2Nb alloy decreased, and the B2 phase transformed from massive to lamellar.

Revealing the impact of Hot Isostatic Pressing temperature on the microstructure and mechanical characteristics of Selective Laser Melted CuAlNiMn shape memory alloy

The present research examines the impact of temperature during Hot Isostatic Pressing (HIP) on the mechanical, microstructure, and density characteristics of Cu-based shape memory alloys (SMAs) made by Selective Laser Melting (SLM). HIP improved the density of the built components by 11.5 %, with a reduction in density with an increase in HIP temperature. Pore aspect ratio analysis revealed non-spherical pores at higher temperatures, while spherical and small pores were observed at 950 °C. SEM analysis demonstrated the disappearance of shrinkage porosity and an increase in grain size with higher HIP temperatures. XRD analysis confirmed phase transformation and variation in crystallite size with an increase in HIP temperature. After HIP treatment, microhardness and tensile strength significantly improved, with the 950 °C sample showing the highest values.

A comparative study on anisotropy of additively manufactured CoCrNi medium-entropy alloys by hot isostatic pressing and ultrasonic impact treatment

The anisotropy properties of samples in different direction is found in additively manufactured (AM) CoCrNi medium-entropy alloys (MEAs). In this study, the laser direct energy deposition AM CoCrNi MEAs have been subjected to two alternative processing methods: hot isostatic pressing (HIP) and ultrasonic impact treatment (UIT). The effect of HIP and UIT on the microstructure, grain orientation, grain boundary distribution, phase distribution and mechanical properties of AM CoCrNi MEAs were systematically studied. The results show that HIP decreased the partial mechanical anisotropy of AM CoCrNi MEAs, and YS was significantly reduced. The main reason is that the HIP induces the formation of large number of Cr2O3 particles, and transformation of low-angle grain boundaries (LAGBs) into high-angle grain boundaries (HAGBs). Surprisingly, both the yield strength (YS) and ultimate tensile strength (UTS) of the AM CoCrNi MEAs were increased when the UIT was added after every laser deposition of one layer (UIT-1). This is due to the combined effect of quasi-static loading and ultrasonic oscillations of UIT, which results in the dislocation multiplication and the formation of a large number of substructures. In addition, the above strengthening phenomena also lead to decrease partial mechanical anisotropy of AM CoCrNi MEAs.

High cycle fatigue behavior of additively manufactured Ti-6Al-4V alloy with HIP treatment at elevated temperatures

The fatigue tests at 200 °C and 400 °C were conducted to investigate the elevated-temperature fatigue behavior of additively manufactured (AM) Ti-6Al-4V alloy with hot isostatic pressing (HIP) treatment. Since the manufacturing defects (i.e., pores) were significantly reduced by HIP treatment, no specimen failed from the pores. Consequently, the present AM Ti-6Al-4V alloy behaved superior to that without HIP treatment. Moreover, the specimens exhibited different failure mechanisms at 200 °C and 400 °C. Fatigue crack initiation at 200 °C mainly was due to surface deformation and strain localization, while the cause became fracture of surface oxygen-rich layer at 400 °C.

Effect of hot isostatic pressing and heat treatment on the evolution of precipitated phase and mechanical properties of GH3230 superalloy fabricated via selective laser melting

In this paper, the microstructure and mechanical properties of SLM-GH3230 superalloy treated by different post treatments (single hot isostatic pressing and heat treatments after hot isostatic pressing) were studied. The micro-morphologies show that the grains along building direction after HIP + HT are mainly columnar grains, which is consistent to that after single HIP. The granular precipitates distribute intergranularly and intragranularly after HIP, but gradually re-dissolve into matrix with the increase of the temperature of the post HT processes. XRD and EDS analyses results indicate that the matrix mainly consists of austenitic γ phase and the granular precipitates are mainly M6C carbides enriched in W element. The average grain size decreases after HT compared to that after HIP, and the crystallographic orientation of grains tends to be more uniform. The Vickers hardness decreases after HIP and HIP + HT processes within a certain degree. According to tensile test results, the sample shows a better combination of strength and plastic performance under HIP+1250 °C/30 min processing, which can also be verified by the characteristic of the fracture morphology with more tearing dimples.

Fused deposition modeling of Inconel 625 alloy: Effect of hot isostatic pressing on the microstructure and tensile properties

Inconel 625 alloy was fabricated using fused deposition modeling (FDM), an emerging advanced additive manufacturing (AM) technique. Subsequently, the effects of hot isostatic pressing (HIP) on its microstructure and mechanical properties were investigated. Notably, HIP treatment significantly reduced the defect density, resulting in enhanced tensile ductility.

Performance of Ce:YAG-MgO composite ceramics as high-power LED phosphor densified by non-reactive sintering

A novel white light converter has been successfully synthesized using a non-reactive sintering process to afford a fully densified Ce:YAG-MgO composite ceramic phosphor with high wavelength conversion efficiency under excitation at 450 nm. The composite obtained by HIP (hot isostatic pressing) treatment at 1080 ºC has no residual pores and the XRD (X-ray diffraction) analysis shows that there are no secondary phases other than Ce:YAG and MgO, moreover, the EDS (Energy-dispersive X-ray spectroscopy) analysis indicates no interdiffusion at the Ce:YAG-MgO contact interface. The thermal conductivity of 5–7.5 wt% Ce:YAG-added MgO composites is over 40 W/mK, nearly reaching the theoretical value. Due to the synergetic effect of “the difference in refractive index between MgO and Ce:YAG” and “MgO matrix with strong birefringence”, the excitation light (450 nm) is multiply scattered inside the composite medium, which provides efficient excitation even in a thin medium, resulting in the photoluminescence intensity that is 2.6 times higher than that of transparent Ce:YAG ceramics. This innovative white light converter combines a highly thermal conductive MgO matrix and Ce:YAG phosphor with high emission intensity.

An investigation over microstructure and HIP processing effects on wear performance of pure chromium parts fabricated by laser powder bed fusion

Chromium (Cr) and its alloys have long been valued for their exceptional properties, including corrosion resistance and high-temperature stability, rendering them indispensable in industrial applications such as chemical processing, energy production, and aerospace. However, due to the difficulties in Cr-based alloy manufacturing, there is a need for novel manufacturing methodologies. Additive Manufacturing (AM) emerges as a promising approach, particularly Laser Powder Bed Fusion (LPBF), which allows for intricate designs, reduced material waste, and simplified assembly. However, certain issues still need to be addressed, including defects like cracks and porosities in the manufactured parts. Post-processing techniques such as Hot Isostatic Pressing (HIP) have gained prominence for enhancing the material properties and quality of AM parts, including those produced using LPBF. HIP treatments are effective in eliminating internal pores, although some challenges remain, notably the presence of trapped argon and grain coarsening side effects of HIP process parameters. This study focuses on LPBF-processed pure chromium parts with crystallographic texture and investigates their properties after HIP treatment, including microstructure, hardness, and tribological performance. According to the obtained results: the HIP process reduced cracks, especially in the center region, but increased gaps in the side region. HIP also hindered grain realignment, limiting grain growth, and resulting in high HAGB density and low MUD values. Elevated HIP processing pressure negatively affected tribological performance due to increased grain size, and reduced hardness. This study, for the first time, realized the effect of HIP conditions on the microstructure and tribological performance of LPBF-processed pure Cr.

Microstructure and Mechanical Properties of a Novel Al-Mg-Sc-Ti Alloy Fabricated by Laser Powder Bed Fusion.

(TiH2 + ScH3)/Al-Mg composite powders with different Ti contents were produced by ball milling. These composite powders were fabricated to cube and cuboid shape samples via a laser powder bed fusion process with optimal processing parameters. The TiH2 and ScH3 particles underwent dehydrogenation during the laser powder bed fusion process, and these composite powders ultimately formed Al-Mg-Sc-Ti alloys. The relative density, printability, microstructure, hardness and tensile properties of these alloy samples were investigated. The results show that these Al-Mg-Sc-Ti alloys have lower hot-crack sensitivity, having fine equiaxed grains. An Al18Mg3(Ti,Sc)2 intermetallic phase and in situ L12-Al3(Sc,Ti) precipitations formed during the laser powder bed fusion process, which is beneficial for nucleation and dispersion strengthening. The ultimate tensile strength of the Al-Mg-0.7Sc-1.0Ti alloy was 313.6 MPa with an elongation of 6.6%. During the hot isostatic pressing treatment, most of the Mg element precipitated from the matrix and changed the Al3(Sc,Ti) into a Al18Mg3(Ti,Sc)2 precipitate completely. The Al-Mg-Sc-Ti alloys were nearly fully dense after the hot isostatic pressing treatment and exhibited better mechanical properties. The ultimate tensile strength of the Al-Mg-0.7Sc-1.0Ti was 475 MPa with an elongation of 8.5%.

Effect of hot isostatic pressing on microstructure and properties of high chromium K648 superalloy manufacturing by extreme high-speed laser metal deposition

High chromium superalloys have good overall mechanical properties and are widely used in critical hot-end components. The current manufacturing process still faces the problem of low forming efficiency. Extreme high-speed laser metal deposition (EHLMD) is a new and efficient additive manufacturing technology that can quickly and directly shape the direct forming of difficult-to-process materials. However, EHLMD still possesses some inter-layer defects in EHLMD alloy due to its excessively fast scanning speed, implying that there is potential for further improvement in its properties. Hot isostatic pressing (HIP) as a post-heat treatment is primarily used for the removal of defects in additive manufacturing components. In this study, the defects, microstructure, and properties of the EHLMD K648 superalloy using Micro-CT, XRD, SEM and TEM under HIP treatment were investigated. The results show that the porosity of the HIP EHLMD K648 superalloy decreased, and slender needle-shaped α-Cr phase, γ′ phase and coarse M6C carbides were precipitated. The tensile strength of the HIP EHLMD K648 superalloy increased by about 240 MPa. However, its plasticity was reduced. To further improve the plasticity of the HIP EHLMD K648 superalloy, subsequent heat treatment was carried out. The outcomes of this study are expected to promote the manufacturing of high-quality chromium superalloys and the development of EHLMD technology.