Options for Improving Performance of Additively Manufactured Nickel-Base Superalloys for Gas Turbine Applications

Abstract Additive manufacturing (AM) has been increasingly used for gas turbine (GT) components over the last decade. Many different components can be successfully designed, printed, and used in the gas turbine. However, there still exist questions on the use of AM components in hot-section areas. These components are typically fabricated from nickel-base superalloys that are known to have superior mechanical properties at elevated temperatures (e.g., creep and fatigue). Research over the last decade has been primarily focused on the printability of nickel-base superalloys, and there still exists a gap in understanding the high temperature processing–structure–properties–performance relationships of these alloy systems. This study evaluates the effect of processing methods, such as laser-based powder bed fusion (LBPBF) and electron beam powder bed fusion (EBPBF), on the resulting microstructure and time dependent mechanical properties of a nickel-base superalloy (ABD®900). Material after each build was subsequently heat treated using both near-solvus (at or slightly below the gamma prime solvus temperature) and super-solvus (above gamma prime solvus temperature) conditions. Multistep aging was then carried out to produce a bi-modal distribution of gamma prime precipitates as is typical in similar alloys. Microstructure was evaluated in both the as-built and fully heat-treated conditions for each processing technique. Mechanical testing was conducted to evaluate the effects of AM build methods, microstructure, and heat treatment on high temperature mechanical properties. The results show that there are several methods which can be used to improve the performance of components built using AM. The creep testing results for ABD900-AM clearly show an improvement in properties (rupture life and ductility) at all test conditions compared to testing in the prior AM alloy of the same class. A super-solvus heat treatment improved creep rupture strength by ∼3× in the LBPBF material compared to the near-solvus heat treatment. These findings provide directions for future studies to advance the overall state of gas turbine technology by enabling ABD®900-AM material and other AM alloys to be used in more innovative hot-section components.