@article {2206, title = {Analysis of the high cracking resistance of a Co Ni superalloy during laser additive manufacturing}, journal = {Scripta Materialia}, volume = {239}, year = {2024}, pages = {115770}, abstract = {

A newly developed CoNi-based superalloy is demonstrated to be tolerant of a wide range of laser powder bed fusion print conditions, with limited defect content and high relative densities. These promising traits motivated investigation of the structural uniformity in samples printed at the upper end of the scan velocity processing window (\>Image 1). A new misorientation metric, starting reference orientation deviation (SROD), was calculated from Image 2-scale 3D microstructure information to examine structure evolution during epitaxial growth of columnar grains. Misorientations of \>20\° were observed within the large columnar grains that grew through multiple build layers. The SROD observations highlight the CoNi superalloy\&$\#$39;s ability to plastically deform to high levels, as evidenced by misorientation gradients, across the range of temperatures experienced in laser additive manufacturing. Misorientation gradients within the columnar grain structure are high relative to Ni base superalloys, allowing for strengthening with high volume fractions of L12 precipitates.

}, keywords = {3D EBSD, Rapid solidification, Superalloy}, issn = {1359-6462}, doi = {https://doi.org/10.1016/j.scriptamat.2023.115770}, url = {https://www.sciencedirect.com/science/article/pii/S1359646223004918}, author = {James Lamb and Kira M. Pusch and Andrew T. Polonsky and St{\'e}phane A.J. Forsik and Ning Zhou and Austin D. Dicus and Remco Geurts and McLean P. Echlin and Tresa M. Pollock} } @article {2196, title = {Navigating the BCC-B2 refractory alloy space: Stability and thermal processing with Ru-B2 precipitates}, journal = {Acta Materialia}, volume = {265}, year = {2024}, pages = {119628}, abstract = {

Refractory multi-principal element alloys (RMPEAs) could provide next-generation high temperature alloys, but their ductility and high temperature strength need significant improvement. Emulating superalloy \γ-\γ\’ microstructures, RMPEAs combining a ductile BCC matrix with embedded B2 precipitates for strengthening could meet this goal. Two-phase BCC-B2 RMPEAs have recently been demonstrated, but the B2 phase typically exhibits insufficient thermodynamic stability for operating temperatures \≥1300 \°C. Using high-throughput CALPHAD predictions, we screen across 3,500 potential BCC-B2 systems. Promising compositions are predicted for alloys combining Ru-based B2s with refractory BCC elements. A total of 20 such compositions were arc-melted to characterize their as-cast and heat-treated microstructures. In these alloys, the RuHf B2 exhibits exceptional stability beyond 1900 \°C but cannot be solutionized. By contrast, RuTi does solutionize and reprecipitate between 1300 and 1900 \°C, providing a robust thermal processing pathway. RuAl can be solutionized but also tends to form competing intermetallic phases. Altogether, Ru-B2 RMPEAs offer great design flexibility and surpass the stability and thermal processability of previously studied BCC-B2 refractory alloys.

}, keywords = {B2 phase, Calphad, Combinatorial, High temperature materials, Precipitation strengthening, Refractory multi principal element alloys, Thermal processing}, issn = {1359-6454}, doi = {https://doi.org/10.1016/j.actamat.2023.119628}, url = {https://www.sciencedirect.com/science/article/pii/S1359645423009564}, author = {Sebastian A. Kube and Carolina Frey and Chiyo McMullin and Ben Neuman and Kaitlyn M. Mullin and Tresa M. Pollock} } @article {2211, title = {Rapid Screening of Single Phase Refractory Alloys Under Laser Melting Conditions}, journal = {Materials \& Design}, year = {2024}, pages = {112726}, abstract = {

Refractory alloys can be difficult to fabricate by laser-based manufacturing methods due to their high melting temperatures, high interstitial solubility, and propensity for low temperature brittleness. Laser-based processes, such as welding and additive manufacturing (AM), yield similar populations of defects, including microsegregation and solidification and solid-state cracking. Given the extreme challenges and cost associated with the production of refractory powders, this research aimed to develop a rapid screening methodology that combines predictive defect formation metrics with single track melting experiments. A flexible single laser track melting platform was designed to perform screening experiments on conventional and multi-principal element refractory alloys across a wide range of laser energy inputs. The platform was employed to investigate laser melting on solid substrates, or on a substrate with a single layer of powder feedstock, and is demonstrated with the highly fabricable Nb-base alloy C103. Preliminary investigations are performed on refractory multi-principal element alloys in the Hf-Mo-Nb-Ta-Ti family, and significant differences in cracking resistance and solidification morphology are observed. Implications for future alloy design and processing strategies for defect-resistant refractory alloys for AM are discussed.

}, keywords = {Additive manufacturing, high entropy alloy, multi-principal element alloy, refractory alloys, solid-state cracking, solidification cracking}, issn = {0264-1275}, doi = {https://doi.org/10.1016/j.matdes.2024.112726}, url = {https://www.sciencedirect.com/science/article/pii/S0264127524000984}, author = {Kaitlyn M. Mullin and Carolina Frey and James Lamb and Sophia K. Wu and McLean P. Echlin and Tresa M. Pollock} } @article {1811, title = {Single crystal elastic constants of additively manufactured components determined by resonant ultrasound spectroscopy}, journal = {Materials Characterization}, volume = {192}, year = {2022}, pages = {112244}, abstract = {

Bayesian inference with Sequential Monte Carlo was used to determine the single crystal elastic constants of additively manufactured (AM) cobalt-nickel-based superalloy specimens from only the resonant frequencies and texture data. This novel framework enables the quantification of the single crystal elastic constants for AM and polycrystalline specimens using only electron backscatter diffraction (EBSD) and Resonant Ultrasound Spectroscopy (RUS), avoiding the expense of bulk single crystal fabrication or synchrotron experiments. A parallelizable and open-source Python package (SMCPy) was used to perform Bayesian inference of the single crystal elastic constants from resonant frequencies of AM specimens. The single crystal elastic constants determined from AM cobalt-nickel-base superalloy specimens were validated with measurements of the single crystal elastic constants on a bulk single crystal specimen. EBSD texture data was used to determine the single crystal elastic constants from the resonant frequencies of AM specimens, and validated with neutron diffraction data by considering the experimental uncertainty in both the EBSD and neutron diffraction data. The robustness of this framework for varied texture orientations relative to the build direction (BD) was demonstrated for AM specimens printed at 0\° and 20\° BD-inclinations.

}, issn = {1044-5803}, doi = {https://doi.org/10.1016/j.matchar.2022.112244}, url = {https://www.sciencedirect.com/science/article/pii/S1044580322005265}, author = {Jeff Rossin and Patrick Leser and Kira Pusch and Carolina Frey and Sven C. Vogel and Alec I. Saville and Chris Torbet and Amy J. Clarke and Samantha Daly and Tresa M. Pollock} } @article {1741, title = {Bayesian inference of elastic constants and texture coefficients in additively manufactured cobalt-nickel superalloys using resonant ultrasound spectroscopy}, journal = {Acta Materialia}, volume = {220}, year = {2021}, pages = {117287}, abstract = {

Bayesian inference with sequential Monte Carlo is used to quantify the orientation distribution function coefficients and to calculate the fully anisotropic elastic constants of additively manufactured specimens from only the experimentally-measured resonant frequencies. The parallelizable and open-source SMCPy Python package enabled Bayesian inference within this new modeling framework, resulting in an order of magnitude reduction of the computation time for an 8-core machine. Residual stress-induced shifts on the resonant frequencies were explicitly accounted for during the Bayesian inference, enabling the estimation of their effect on the resonant frequencies without a stress-relief heat treatment. Additively manufactured cobalt-nickel-base superalloy (SB-CoNi-10C) specimens were sectioned at multiple inclinations relative to the build direction and scanned with resonant ultrasound spectroscopy to demonstrate characterization of any arbitrarily textured cubic microstructure through the resonant frequencies. The orientation distribution function coefficients of the textured polycrystalline microstructure were estimated in tensorial form to calculate both the 2nd order Hashin-Shtrikman bounds and the self-consistent estimate of the elastic constants, enabling accurate determination of all 21 possible independent elastic constants through the convergence constraints of the texture. Pole figures generated directly from the calculated texture coefficients showed good agreement with experimentally measured textures.

}, keywords = {Additive manufacturing, Bayesian inference, Parallel computing, Residual stress, Resonance ultrasound spectroscopy, Sequential monte carlo, Texture characterization}, issn = {1359-6454}, doi = {https://doi.org/10.1016/j.actamat.2021.117287}, url = {https://www.sciencedirect.com/science/article/pii/S1359645421006674}, author = {Jeff Rossin and Patrick Leser and Kira Pusch and Carolina Frey and Sean P. Murray and Chris J. Torbet and Stephen Smith and Samantha Daly and Tresa M. Pollock} }