Selective Laser Melting Parameters Research Articles

Study on the fabricating process of LaB6 reinforced Ti6Al4V by selective laser melting

In this study, LaB6-reinforced Ti6Al4V was successfully fabricated by the selective laser melting (SLM) process. TiB and La2O3 with particle-like shapes formed uniformly after the in-situ reaction of LaB6 and Ti6Al4V. The sizes of the TiB and La2O3 particles were around 1 µm and 200 nm, respectively. Due to a combined strengthening effect of the micrometer-scale and nanoscale reinforcements, the mechanical properties of the LaB6/Ti6Al4V samples were enhanced significantly. However, the effect was highly related to the SLM parameters. As the laser power increased, the TiB changed from particle to needle-like shape and La2O3 tended to aggregate and grow into a larger size. Besides, the martensite α-Ti also became coarser, which was disadvantageous to the mechanical performance. The desired inner structure can be obtained by adjusting the processing parameters of the SLM. The best mechanical performance of the SLM LaB6/Ti6Al4V samples was achieved at the laser power of 260 W and the scanning speed of 500 mm/s. The maximum tensile strength and Vickers hardness were 1337.1 MPa and 477.62 HV, respectively, which outperformed the other counterparts significantly. Thus, the results suggest that the in-situ reaction of LaB6 and Ti6Al4V can improve the mechanical properties of the Ti6Al4V alloys effectively.

Selective laser melting of oxide dispersion strengthened MA956 alloy and its surface finishing by magnetic field assisted finishing

Selective laser melting (SLM) is a prominent metal additive manufacturing (AM) capable of processing a myriad of engineering materials with high precision and design freedom. However, similar to other AM processes, poor surface finishing has been an omnipresent problem in SLM technology. In this study, magnetic field assisted finishing (MAF) was used to finish SLM fabricated oxide dispersion strengthened (ODS) MA956, an iron‑chromium‑aluminum alloy. The effect of laser processing parameters on part density and surface roughness was first studied. Using a multi-objective optimization technique, the optimal parameters to obtain the highest density and lowest surface roughness were determined. Finally, MAF was applied to the parts built with the obtained optimal SLM parameters, but without significant improvement on the surfaces of as-printed samples. Hence, the surfaces of as-printed samples were post-processed (ground) to yield better initial surface conditions prior to MAF. The effect of initial roughness, iron particles size, and abrasive size on MAF performance was studied. Initial roughness had the most dominant effect followed by abrasive size. The underlying mechanism behind the dependency on initial roughness on final surface quality was analyzed by studying the change on the surface profiles with different starting initial roughness. The initial roughness required for MAF to be effective was determined. Using the optimal processing conditions, MAF was applied to the post-processed samples to attain the final average surface roughness (Ra) as little as 0.36 μm starting from initial average roughness (Ra) of 1.53 μm.

Evaluation of Selected Technological Parameters for Selective Laser Melting of AlSi10Mg Metal Powder

Reusing the powder across consecutive route cycles is typical in a Selective Laser Melting (SLM) process since it is more sustainable and cost-effective. The theoretical part of the paper is oriented on the explanation of the SLM method principle, construction, and parameters of the device Renishaw AM250 used for manufacturing samples made of AlSi10Mg aluminium alloy. The experimental part focuses on evaluating powders that had been used in the process for a long time with periodic ‘rejuvenation’. The main aim will be to monitor whether the samples will be affected and if they achieved the required quality of mechanical properties and compare results with virgin powder and manufacturer sheets for virgin powders. The experimental part further describes the procedures and analysis of the microstructure of the samples. AlSi10Mg aluminium alloy was chosen because of an assumption that it will be sensitive to increased oxygen content. A strong affinity for oxygen uptake exists in AlSi10Mg. Therefore, preventing the contamination, careful handling is required.

Microstructure, Properties and Crack Suppression Mechanism of High-speed Steel Fabricated by Selective Laser Melting at Different Process Parameters

To enrich material types applied to additive manufacturing and enlarge application scope of additive manufacturing in conformal cooling tools, M2 high-speed steel specimens were fabricated by selective laser melting (SLM). Effects of SLM parameters on the microstructure and mechanical properties of M2 high-speed steel were investigated. The results showed that substrate temperature and energy density had significant influence on the densification process of materials and defects control. Models to evaluate the effect of substrate temperature and energy density on hardness were studied. The optimized process parameters, laser power, scan speed, scan distance, and substrate temperature, for fabricated M2 are 220 W, 960 mm/s, 0.06 mm, and 200 ℃, respectively. Based on this, the hardness and tensile strength reached 60 HRC and 1000 MPa, respectively. Interlaminar crack formation and suppression mechanism and the relationship between temperature gradient and thermal stress were illustrated. The inhibition effect of substrate temperature on the cracks generated by residual stresses was also explained. AM showed great application potential in the field of special conformal cooling cutting tool preparation.

Achieving ultra-high strength and ductility in Mg–9Al–1Zn–0.5Mn alloy via selective laser melting

Fabrication of the Mg–9Al–1Zn-0.5Mn alloy with excellent mechanical performance using selective laser melting (SLM) technology is quite difficult owing to the poor weldability and low boiling point. To address these challenges and seek the optimal processing parameters, response surface methodology was systematically utilized to determine the appropriate SLM parameter combinations. Mg–9Al–1Zn-0.5Mn sample with high relative density (99.5 ± 0.28%) and favorable mechanical properties (microhardness = 95.6 ± 5.28 HV0.1, UTS = 370.2 MPa and At = 10.4%) was achieved using SLM parameters (P = 120 W, v = 500 mm/s and h = 45 μm). Microstructure was primarily constituted by quantities of fine equiaxed grains (i.e., α-Mg phase) and a small amount of β-Al12Mg17 structures (i.e., 4.96 vol%). Samples was dominated by a random texture with numerous spherical β-Al12Mg17 ([21¯1¯0]α// [111]β), long lath-like β-Al12Mg17 ([21¯1¯0]α// [11¯5]β and [1¯011]α// [32¯1¯]β), and short rod-shaped Al8Mn5 nanoparticles. Benefiting from grain boundary strengthening, solid solution strengthening, and precipitation hardening of various nanoparticles (β-Al12Mg17 and Al8Mn5), high-performance Mg–9Al–1Zn-0.5Mn alloy biomedical implants can be fabricated. Precipitation hardening dominates the strengthening mechanism of the SLM Mg–9Al–1Zn-0.5Mn alloy.

Processing Fundamentals and Performance Investigation of Selective Laser Melting of High‐Speed Steel in Reactive N2 Atmosphere

The distinct deposition method of selective laser melting (SLM) enables the near‐net‐shaping of high‐speed steel tools with complex geometries and integrated functions, such as adapted cooling channels, which offers economic advantages and has, thus, attracted considerable attention. However, SLM‐processed high‐speed steels are prone to cracking due to their high carbon and alloying element contents and high internal stresses. Varying the steel composition to stabilize austenite can help to reduce the residual stresses. Herein, the effect of nitrogen atmosphere on the densification behavior, microstructural evolution, and mechanical properties of high‐speed steel in the SLM process is investigated. The results demonstrate that nitrogen can dissolve in the steel. In combination with suitable SLM parameters, this leads to a fully austenitic microstructure with no cracks. After heat treatment, the microstructure of steel transforms into tempered martensite, along with the precipitation of tiny V‐rich M(C,N) carbonitride and V‐rich MC carbide. The hardness and bending strength of the tempered sample reach the highest of 61.3 HRC and 3659 MPa, respectively. Its abrasive resistance is also improved. An alloy design idea is provided that is based on the reactive atmosphere of high‐speed steel and other materials for processing by SLM.

Multiresponse Optimization of Selective Laser Melting Parameters for the Ni-Cr-Al-Ti-Based Superalloy Using Gray Relational Analysis

The selective laser melting technology is of great interest in the aerospace industry since it allows the implementation of more complex part geometries compared to the traditional technologies. This paper presents the results of studies to determine the optimal technological parameters for scanning a Ni-Cr-Al-Ti-based superalloy. However, due to a large number of factors affecting the quality of the parts obtained by selective laser melting technology, the optimization of the technological parameters of the scanning is a difficult task. In this work, the authors made an attempt to optimize the technological scanning parameters which will simultaneously correspond to the maximum values of the mechanical properties ("More is better") and the minimum values of the dimensions of the microstructure defect ("Less is better"). Gray relational analysis was used to find the optimal technological parameters for scanning. Then, the resulting solutions were compared. As a result of the optimization of the technological parameters of the scanning by the gray relational analysis method, it was found that the maximum values of the mechanical properties were achieved simultaneously with the minimum values of the dimensions of a microstructure defect, at a laser power of 250 W and a scanning speed of 1200 mm/s. The authors present the results of the short-term mechanical tests for the uniaxial tension of the cylindrical samples at room temperature.

Densification, Microstructure and Anisotropic Corrosion Behavior of Al-Mg-Mn-Sc-Er-Zr Alloy Processed by Selective Laser Melting

High-performance additives manufactured by Al alloys provide significant potential for lightweight applications and have attracted much attention nowadays. However, there is no research on Sc, Er and Zr microalloyed Al alloys, especially concerning corrosion behavior. Herein, crack-free and dense Al-Mg-Mn-Sc-Er-Zr alloys were processed by selective laser melting (SLM). After optimizing the process parameters of SLM, the anisotropic corrosion behavior of the sample (volume energy density of 127.95 J·mm−3) was investigated by intergranular corrosion (IGC) and electrochemical measurements. The results showed that the XY plane of the as-built sample is less prone to IGC, and it also has a higher open circuit potential value of −901.54 mV, a higher polarization resistance of 2.999 × 104 Ω·cm2, a lower corrosion current of 2.512 μA·cm−2 as well as passive film with superior corrosion resistance compared to the XZ plane. According to our findings, the XY plane has superior corrosion resistance compared to the XZ plane because it has fewer primary phases of Al3(Sc, Er, Zr) and Al2MgO4, which can induce localized corrosion. Additionally, a higher fraction of low-angle grain boundaries (LAGBs) and a stronger (001) texture index along the building direction are also associated with better corrosion resistance of the XY plane.

Nanospikes on Customized 3D‐Printed Titanium Implant Surface Inhibits Bacterial Colonization

Additive manufacturing has opened the door to patient‐tailored orthopedic implants, which can significantly minimize implant failures associated with prosthesis‐to‐bone mismatch. Success of an implant also depends on the choice of implant materials, effective osseointegration, implant quality, and the mechanical properties together with its capability to limit infection due to bacterial contamination. Herein, nanospikes are created on 3D‐printed titanium‐alloyed implant surfaces, which can kill bacteria to minimize any implant‐associated infections. For the first time, orthopedic implants with a fracture to the proximal phalanx are fabricated using selective laser melting (SLM) followed by a heat‐treatment step and the hydrothermal process. It is showed in the results that by optimizing SLM parameters, dimensionally consistent parts can be produced and tensile properties of the 3D‐printed implants can be significantly improved via a simple cyclic heat‐treatment process compared to the traditionally manufactured implants. Nanospikes similar to those present on dragonfly wings fabricated on 3D‐printed implants surface are able to kill above 90% of adhering bacteria by rupturing the membranes upon contact. These results indicate that fabrication of patient‐specific 3D‐printed implants with inherent bactericidal properties has the potential to eliminate postsurgical infections and possible implant failures.

IMPROVING THE MECHANICAL CHARACTERISTICS OF 316L STAINLESS STEEL PRODUCED BY SELECTIVE LASER MELTING AND STUDYING THE EFFECT OF POROSITY ON STRENGTH

The results of experiments on the study of the physical and mechanical properties and microstructure of 316L stainless steel produced by additive technology selective laser melting are obtained. The dependences of the physical and mechanical properties (density, tensile strength, yield strength, elongation to failure, Young's modulus, nano hardness) of 316L steel on the main parameters of the selective laser melting (laser power, scanning speed) are obtained. 316L steel produced by selective laser melting has high mechanical characteristics: tensile strength – 710 MPa; yield strength – 610 MPa; elongation to failure – 48%; relative density – 99.5%, which is comparable to the values obtained for 316L steel produced by traditional methods. These characteristics were obtained using the optimal parameters of selective laser melting: laser power 100 W, scanning speed 200 mm/s, layer thickness 50 ?m, the distance between the scanning tracks is 80 ?m. It is shown that the use of the “volumetric energy density” parameter is usefully for carrying out a primary assessment of technological modes and solving the problem of optimizing the parameters of selective laser melting to obtain a material with high physical and mechanical properties. The nonlinear dependence of the mechanical properties of 316L steel on the main technological parameters can be explained by the influence of porosity arising at non-optimal modes. It is shown that selective laser melting allows controlling the porosity of 316L steel by varying the parameters of the technological mode. Thus selective laser melting makes it possible to produce both a material with a high density close to theoretical values and a material with controlled porosity.

ИССЛЕДОВАНИЕ СТРУКТУРЫ И МЕХАНИЧЕСКИХ СВОЙСТВ ОБРАЗЦОВ, ПОЛУЧЕННЫХ МЕТОДОМ СЕЛЕКТИВНОГО ЛАЗЕРНОГО СПЛАВЛЕНИЯ ИЗ МЕТАЛЛИЧЕСКОГО ПОРОШКА ЖАРОПРОЧНОГО СПЛАВА ВЖ-159 (ХН58МБЮ)

This paper presents the results of determining the optimal parameters of selective laser melting (SLM) of the metal powder of the high-temperature alloy VZh-159 (KhN58MBYu). Empirically and using mathematical methods for planning and analyzing experiments to determine the effect of technological parameters of fusion on the tensile strength of the material, rational SLM modes have been established, namely, laser emission power, hatching, scanning speed. The laser power P (X1) and scanning speed v (X2) were chosen as the main variable parameters of the full-factor experimental design, and the tensile strength σB, MPa (Y), was presented as a dependent variable on the selected factors. The mechanical properties of the samples produced by the SLM were determined, which also depended on the volumetric energy density, which is equal to the ratio of the laser power to the product of the scanning speed, hatching, and layer thickness. During the experiment, it was possible to obtain an acceptable quality indicator - mechanical properties, for a certain range of technological parameters of SLM. A study of the microstructure of the material of produced samples of the VZh-159 (KhN58MBYu) heat-resistant alloy was carried out, and chemical and granulometric analysis of the initial powder was carried out.

Balanced strength-ductility combination and good recoverable strain of Ni50.7Ti49.3 alloy fabricated by high scanning velocity in selective laser melting

Optimizing of process parameters such as high laser power combined with high scanning velocity during selective laser melting (SLM) is appropriate to the demand of high efficiency and high precision fabrication of NiTi alloys. However, the exploration in such process window is inexhaustive yet. In this work, SLM parameters of high laser power combined with high scanning velocity (180 W and 800–1400 mm/s) are adopted to manufacture defect-free Ni 50.7 Ti 49.3 alloy and the microstructure, martensitic transformation, mechanical and functional properties are studied systematically. The microstructure of SLM samples is composed of alternate coarse and fine columnar grains in different regions of molten pool. Unique square grain structure is formed in the top surface. Consequently, the prepared Ni 50.7 Ti 49.3 samples exhibit balanced strength-ductility combination with tensile strength of 804.6–870.0 MPa and ductility of 6.4–8.1%. Good recoverable strain of 3.4%–4.7% and recovery ratio of 83.1%–88.9% is achieved. Basically, the change in the recoverable strain for the prepared samples at different scanning velocities are discussed based on thermodynamics analysis. The findings in this work provide some insights into design and preparation of high-performance NiTi alloys by SLM. • A newly developed selective laser melting parameter window of high laser power combined with high scanning velocity was investigated. • Balanced strength-ductility combination with tensile strength of 804.6–870.0 MPa and ductility of 6.4–8.1% was achieved. • Alternate coarse and fine columnar grains in square grain structure postpone the crack propagation. • Strain recovery via superelasticity or shape memory effect was analyzed based on thermodynamics principle.

Improving the physical and mechanical characteristics of unalloyed titanium VT1-0 and studying the effect of selective laser melting parameters

Comprehensive studies of the physical and mechanical properties and structure of VT1-0 titanium samples processed by selective laser melting have been carried out. High strength characteristics (the ultimate tensile strength of 820 MPa, the yield strength of 710 MPa) have been achieved. These exceed by 2 times the values for this material produced using conventional technology. The formation of the martensitic α'-phase, obtained due to the high crystallization rates realized in selective laser melting process, is the reason for the increase in the mechanical characteristics of titanium VT1-0. Mechanical characteristics of titanium VT1-0 subjected to high-temperature annealing demonstrated a monotonous decrease in strength parameters by 15% and an increase in plastic characteristics by 30%. It is shown that the technology of selective laser melting makes it possible to solve the problem of improving the strength characteristics of unalloyed titanium to create a new class of medical devices. Keywords: unalloyed titanium, VT1-0, additive technology, selective laser melting, density, strength, plasticity, elastic modulus, microstructure, implants for surgery.

Optimization of Selective Laser Melting Process Parameters Via Taguchi's Methods and Gray Relational Analysis for 3D Printing of 18Ni‐300 Maraging Steel

Taguchi methods and gray relational analysis are used to determine optimal processing conditions for the selective laser melting (SLM) of 18Ni‐300 maraging steel. The following SLM process parameters are selected for optimization: laser power (P), scanning speed (v), and hatch spacing (h). Statistical analysis indicates that SLM parameter configuration no. 5 (275 W, 700 mm s−1, 0.08 mm) as most suitable for the simultaneous improvement of tensile strength, elongation (or ductility), hardness, and impact toughness. The order of influence of SLM parameters is identified as follows: . Samples with improved mechanical properties can be produced using configurations with higher linear energy density (). This is because the increased laser energy input facilitates complete melting of metal powder, as well as better interlayer bonding between melt pools. Higher can be achieved by either increasing P or decreasing v. Digital image correlation analysis indicates that tensile test samples with higher porosity exhibit lower ductility due to its inability to accommodate plastic strain accumulation for prolonged durations. Fractography analysis indicates that during tensile loading, cracks will nucleate around the pore perimeter and propagate via microvoid coalescence. Fracture will occur at regions with higher porosity due to it having multiple crack initiation sites.

Selective Laser Melting and Mechanical Properties of Stainless Steels.

Metal additive manufacturing (AM) has been evolving in response to industrial and social challenges. However, new materials are hindered in these technologies due to the complexity of direct additive manufacturing technologies, particularly selective laser melting (SLM). Stainless steel (SS) 316L, due to its very low carbon content, has been used as a standard powder in SLM, highlighting the role of alloying elements present in steels. However, reliable research on the chemical impact of carbon content in steel alloys has been rarely conducted, despite being the most prevalent element in steel. Considering the temperatures involved in the SLM process, the laser-powder interaction can lead to a significant carbon decrease, whatever the processing atmosphere. In the present study, four stainless steels with increasing carbon content-AISI 316L, 630 (17-4PH), 420 and 440C-were processed under the same SLM parameters. In addition to roughness and surface topography, the relationship with the microstructure (including grain size and orientation), defects and mechanical properties (hardness and tensile strength) were established, highlighting the role of carbon. It was shown that the production by SLM of stainless steels with similar packing densities and different carbon contents does not oblige the changing of processing parameters. Moreover, alterations in material response in stainless steels produced under the same volumetric energy density mainly result from microstructural evolution during the process.

Thermal and mechanical properties of selective laser melted and heat treated H13 hot work tool steel

It is attractive to fabricate molds and dies using additive manufacturing (AM) technology because the increased freedom of design makes higher cooling efficiency possible. However, little is known so far about the thermal properties of the tool steels fabricated by AM, as well as how to balance between the thermal and mechanical properties. In this work, an H13 tool steel was processed by selective laser melting (SLM) followed by heat treatments and the thermal and mechanical properties in relation to microstructure were investigated. The as-built H13 showed lower thermal conductivities compared with conventional counterparts and exhibited anisotropy with a lower thermal conductivity along the building direction. Heat treatments generally increased the values of thermal conductivities and largely reduced anisotropy, but the final thermal conductivity differed when using different heat-treating schedules. It was found that porosity, retained austenite, the melt-pool structure and the ultra-fine cellular-columnar microstructure, which were functions of SLM and heat-treating parameters, were factors determining the thermal conductivity of H13. Based on the present study of SLMed H13, it is proposed that a trade-off is necessary between thermal and mechanical properties when designing the processing route.

Effect of process parameters and heat treatment on the microstructure and properties of CuCrZr alloy by selective laser melting

Complex CuCrZr alloy parts with well-matched conductivity and strength can be prepared by adjusting the process parameters of selective laser melting (SLM). Thus, in this study, SLM was used to prepare CuCrZr alloys, and their structure, electrical conductivity, and mechanical properties were analyzed. Moreover, effect of aging treatment on the alloy structure was investigated. With the laser power of 400 W, scanning speed of 300 mm/s, and scanning distance of 80 μm, an CuCrZr alloy sample with a maximum relative density of 99.15% and elongation of 71.7% was obtained by SLM. After direct age hardening (DAH) at 480 °C for 2 h, the conductivity and strength of the alloy increased significantly. In particular, the conductivity increased from 22.16%IACS to 72.8%IACS, indicating an overall increase of 228.5%. Meanwhile, the strength increased from 265.5 to 612.0 MPa. From the backscatter diffraction analysis, the small-angle grain boundaries increased after aging, and the crystal orientation changed from <101> to <111>. During direct aging, a large amount of nanoscale Cr phase was precipitated from the supersaturated solid solution, which increased the strength of the alloy. Further, precipitation strengthening was determined to be the main alloy strengthening mechanism. Moreover, the reduction in the solid solution content reduced the electron scattering effect and increased the overall conductivity of the alloy.

A dimensionally augmented and physics-informed machine learning for quality prediction of additively manufactured high-entropy alloy

Selective laser melting (SLM) additive manufacturing (AM) is widely used due to its significant advantages in designing and manufacturing special-shaped complex components. The process parameters of SLM determine the quality of as-built parts, but it is difficult to establish an accurate and reliable mathematical model to connect process parameters with the quality of as-built parts. However, data-driven machine learning can effectively solve the analysis and prediction problem of complex process. Therefore, a machine learning (ML) prediction method based on dimensionality augmentation and physical information is proposed, which connects the process parameters (laser power, hatching space, scanning speed, and layer thickness) of SLM with the quality characteristics (top layer surface roughness and relative density) of as-built parts. The four process parameter features (4-dimensional features) are expanded to high-dimensional features through feature engineering to characterize the quality of as-built parts. In addition, the physical information of powder melting forming in SLM process is fused with ML algorithm, the theory-guided ML is used to improve the prediction accuracy of the model. In this paper, the CoCrFeNiMn high-entropy alloy as-built samples dataset is used for network training of four ML algorithms, and three assessment indexes are used to evaluate the prediction model. The results show that dimensionally augmented and physics-informed ML model has better prediction accuracy and generalization ability. The proposed method can also provide guidance for optimizing process parameters.

Research on forming technology and experiment of high strength aluminum alloy locomotive traction gearbox

Gearbox is a widely used component in mechanical transmission and plays a vital role in the operation of locomotive. With the development of aluminum alloy materials and molding technology, the monolithic casting gearbox has a widely application prospect. This paper focuses on the manufacturing method of Selective Laser Melting processing for high strength aluminum alloy locomotive traction gearbox. Firstly, the influence factors of laser melting process on the placement angle, support type and support spacing are studied through orthogonal experimental design. It is found that the placement angle has the greatest impact on the forming accuracy, the support spacing takes the second place, and the support type has the least impact on the forming accuracy. When the placement angle is 45°, the support spacing is 1 mm, the steel wire support is added to the support type, which has the least impact on the forming accuracy. Then, the processing ability of the whole box structure is verified by using the Fused Deposition Modeling technology. With using the optimized optimal parameter combination, it can be found that the volume of the printing box is 100 cm3, the mass is 280 g, the surface roughness is 6 μm, and the precision is 0.15 mm. Then the laser melting forming process is carried out in the selected box area. Through experimental analysis, a prototype is developed. At the same time, the process parameters of selective laser melting forming for the whole box structure can be obtained.

Development and additive manufacturing of oxide dispersion strengthened inconel 718: Thermochemical and experimental studies

In this study, a new grade of Inconel 718 alloy (IN718) strengthened by nano-oxides has been designed and produced. The alloy composition of 0.3 wt% Y 2 O 3 – IN718 has been determined using CALPHAD-based thermochemical modeling approach. Designed ODS-IN718 alloy is produced by Selective Laser Melting (SLM) method with various power and velocity values to determine the best process parameters for this system. The SLM parameters are optimized for the production of ODS-IN718 alloy. To dissolve the non-equilibrium phases, which are detrimental to the mechanical properties, and maximize the number densities of nano-oxide and other strengthening phases of γ'/γ″, various heat treatment processes are applied based on the thermochemical calculations. The samples which are solutionized at 1050 °C for 1 h followed by aging at 650 °C for 5 h exhibit the best microstructural and mechanical properties. Tensile tests demonstrate that the strength and ductility of the solutionized and aged samples are much improved compared to the standard solutionized and double aged samples due to the fine and uniform microstructure, especially at elevated temperatures. It is observed that experimental results are consistent with the thermochemical modeling calculations. This clearly shows the promise of thermochemical calculations incorporating various databases for designing new alloy systems with nano-oxide strengthening. • A novel ODS-IN718 alloy is designed by thermochemical calculations and produced by selective laser melting (SLM) method. • A novel heat treatment is designed for maximizing number densities of nano-oxides and strengthening precipitates, γ'/γ″. • Y-Ti-O nano-oxides are detected in both as built and heat-treated states. • Experimental results are concordant with thermochemical calculations. • Alloy shows high microhardness, high density (>99%) and compatibility for production with SLM method.