Laser Powder Bed Fusion of K418 Superalloy: Process, Microstructure, Texture Feature, and Mechanical Property

Laser Powder Bed Fusion (LPBF) is one of the most promising additive manufacturing (AM) technologies using metal powders. It has been increasingly applied in variety of industrial and engineering fields, including but not limited to aviation, aerospace, nuclear energy, automobiles, medical, molding, shipping, and so on. In this work, the influence of laser process parameters on the microstructure, textural features, and their resulting effect on the macroscopic mechanical properties of LPBF-manufactured K418 samples was investigated experimentally. OM, SEM, and X-ray diffraction were used to characterize the microstructure evolution, and EBSD was used to identify the crystal texture of the as-built K418 samples. The effect relationship between process, microstructure, and properties was investigated using mechanical property testing. Furthermore, the volumetric energy density VED was considered as a comprehensive evaluation index to reflect the effects of the main laser process parameters on the microstructure and mechanical behavior of LPBF-manufactured K418 samples, including scanning speed v, laser power P, layer thickness t, and hatch space H. The results show that as the volumetric energy density VED increases, the microstructure morphology of the LPBF-manufactured K418 sample evolves: clustered columnar grains → coarsened columnar grains → ultrafine columnar grains, and the mechanical properties of the LPBF-manufactured K418 sample improve, owing to the ultrafine elongated columnar grains and a strong {001} <100> cubic texture.