Effect of directed energy deposition processing parameters on laser deposited Inconel® 718: Microstructure, fusion zone morphology, and hardness

Nathan A. Kistler; Abdalla R. Nassar; Edward W. Reutzel; David J. Corbin; Allison M. Beese

doi:10.2351/1.4979702

Effect of directed energy deposition processing parameters on laser deposited Inconel^® 718: Microstructure, fusion zone morphology, and hardness

Nathan A. Kistler, Abdalla R. Nassar, Edward W. Reutzel, David J. Corbin, Allison M. Beese

Research output: Contribution to journal › Article › peer-review

53 Scopus citations

Abstract

Single-bead, laser-deposited Inconel^® 718 tracks atop substrates of the same composition were studied to ascertain the influence of laser power, processing speed, working distance, and substrate preheat on the fusion zone geometry, microstructure, and hardness. Modifying working distance encompassed both a change in powder flow distribution and beam diameter. Laser power and processing speed linearly affected fusion zone width and area, though laser power was found to have the most significant effect of all processing parameters. Preheating the substrates increased the width of the fusion zone by an average of 16% and led to a more uniform hardness throughout. The fusion zone cross-section was found to morph from semicircular to double-parabolic (wavy) with increasing laser power. This was attributed to surface tension induced Marangoni flow and the influence of surface-activated species on surface tension. The applicability of coupled parameters, including linear heat input and normalized enthalpy were investigated. Given the limited data available on the influence of processing parameters, particularly working distance and substrate temperature, on fusion zone geometry and hardness, results reported here may aid experimentalists and modelers working on cladding and additive manufacturing processes.

Original language	English (US)
Article number	022005
Journal	Journal of Laser Applications
Volume	29
Issue number	2
DOIs	https://doi.org/10.2351/1.4979702
State	Published - May 1 2017

All Science Journal Classification (ASJC) codes

Electronic, Optical and Magnetic Materials
Atomic and Molecular Physics, and Optics
Biomedical Engineering
Instrumentation

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@article{075322a0858a4e23877584369767677f,

title = "Effect of directed energy deposition processing parameters on laser deposited Inconel{\textregistered} 718: Microstructure, fusion zone morphology, and hardness",

abstract = "Single-bead, laser-deposited Inconel{\textregistered} 718 tracks atop substrates of the same composition were studied to ascertain the influence of laser power, processing speed, working distance, and substrate preheat on the fusion zone geometry, microstructure, and hardness. Modifying working distance encompassed both a change in powder flow distribution and beam diameter. Laser power and processing speed linearly affected fusion zone width and area, though laser power was found to have the most significant effect of all processing parameters. Preheating the substrates increased the width of the fusion zone by an average of 16% and led to a more uniform hardness throughout. The fusion zone cross-section was found to morph from semicircular to double-parabolic (wavy) with increasing laser power. This was attributed to surface tension induced Marangoni flow and the influence of surface-activated species on surface tension. The applicability of coupled parameters, including linear heat input and normalized enthalpy were investigated. Given the limited data available on the influence of processing parameters, particularly working distance and substrate temperature, on fusion zone geometry and hardness, results reported here may aid experimentalists and modelers working on cladding and additive manufacturing processes.",

author = "Kistler, {Nathan A.} and Nassar, {Abdalla R.} and Reutzel, {Edward W.} and Corbin, {David J.} and Beese, {Allison M.}",

note = "Funding Information: The authors would like to acknowledge the Office of Naval Research, under Contract No. N00014-11-1-0668. This material is based on research sponsored by Air Force Research Laboratory under Agreement No. FA8650-12-2-7230. The U.S. Government is authorized to reproduce and distribute reprints for Governmental purposes notwithstanding any copyright notation thereon. The views and conclusions contained herein are those of the authors and should not be interpreted as necessarily representing the official policies or endorsements, either expressed or implied, of Air Force Research Laboratory or the U.S. Government. Ed Good, Kyle Snyder, and Gabrielle Gunderman from the Pennsylvania State University Center for Innovative Material Processing Through Direct Digital Deposition (CIMP-3D) are thanked for their assistance in metallographic preparation and hardness measurements. Stephen Brown and Jacob Snyder from the Pennsylvania State University Applied Research Lab are thanked for the characterization of powder flow. The authors also acknowledge the support of Tom McDonald and Optomec in the completion of this work. Publisher Copyright: {\textcopyright} 2017 Laser Institute of America.",

year = "2017",

month = may,

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doi = "10.2351/1.4979702",

language = "English (US)",

volume = "29",

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T1 - Effect of directed energy deposition processing parameters on laser deposited Inconel® 718

T2 - Microstructure, fusion zone morphology, and hardness

AU - Kistler, Nathan A.

AU - Nassar, Abdalla R.

AU - Reutzel, Edward W.

AU - Corbin, David J.

AU - Beese, Allison M.

N1 - Funding Information: The authors would like to acknowledge the Office of Naval Research, under Contract No. N00014-11-1-0668. This material is based on research sponsored by Air Force Research Laboratory under Agreement No. FA8650-12-2-7230. The U.S. Government is authorized to reproduce and distribute reprints for Governmental purposes notwithstanding any copyright notation thereon. The views and conclusions contained herein are those of the authors and should not be interpreted as necessarily representing the official policies or endorsements, either expressed or implied, of Air Force Research Laboratory or the U.S. Government. Ed Good, Kyle Snyder, and Gabrielle Gunderman from the Pennsylvania State University Center for Innovative Material Processing Through Direct Digital Deposition (CIMP-3D) are thanked for their assistance in metallographic preparation and hardness measurements. Stephen Brown and Jacob Snyder from the Pennsylvania State University Applied Research Lab are thanked for the characterization of powder flow. The authors also acknowledge the support of Tom McDonald and Optomec in the completion of this work. Publisher Copyright: © 2017 Laser Institute of America.

PY - 2017/5/1

Y1 - 2017/5/1

N2 - Single-bead, laser-deposited Inconel® 718 tracks atop substrates of the same composition were studied to ascertain the influence of laser power, processing speed, working distance, and substrate preheat on the fusion zone geometry, microstructure, and hardness. Modifying working distance encompassed both a change in powder flow distribution and beam diameter. Laser power and processing speed linearly affected fusion zone width and area, though laser power was found to have the most significant effect of all processing parameters. Preheating the substrates increased the width of the fusion zone by an average of 16% and led to a more uniform hardness throughout. The fusion zone cross-section was found to morph from semicircular to double-parabolic (wavy) with increasing laser power. This was attributed to surface tension induced Marangoni flow and the influence of surface-activated species on surface tension. The applicability of coupled parameters, including linear heat input and normalized enthalpy were investigated. Given the limited data available on the influence of processing parameters, particularly working distance and substrate temperature, on fusion zone geometry and hardness, results reported here may aid experimentalists and modelers working on cladding and additive manufacturing processes.

AB - Single-bead, laser-deposited Inconel® 718 tracks atop substrates of the same composition were studied to ascertain the influence of laser power, processing speed, working distance, and substrate preheat on the fusion zone geometry, microstructure, and hardness. Modifying working distance encompassed both a change in powder flow distribution and beam diameter. Laser power and processing speed linearly affected fusion zone width and area, though laser power was found to have the most significant effect of all processing parameters. Preheating the substrates increased the width of the fusion zone by an average of 16% and led to a more uniform hardness throughout. The fusion zone cross-section was found to morph from semicircular to double-parabolic (wavy) with increasing laser power. This was attributed to surface tension induced Marangoni flow and the influence of surface-activated species on surface tension. The applicability of coupled parameters, including linear heat input and normalized enthalpy were investigated. Given the limited data available on the influence of processing parameters, particularly working distance and substrate temperature, on fusion zone geometry and hardness, results reported here may aid experimentalists and modelers working on cladding and additive manufacturing processes.

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Effect of directed energy deposition processing parameters on laser deposited Inconel^® 718: Microstructure, fusion zone morphology, and hardness

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