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Fatigue crack growth resistance of a mesoscale composite microstructure Haynes 282 fabricated via electron beam melting additive manufacturing

  • Metal Additive Manufacturing
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Abstract

Materials synthesis via additive manufacturing gives unprecedented control over the solidified microstructure. While a number of studies have demonstrated the ability to produce spatially varying microstructures, little work exists to understand the behavior of such “composite” materials. In this work, we utilized electron beam melting to process Ni-based superalloy Haynes 282 and produce compact tension samples with a spatially varying mesoscale structure. Fatigue crack growth experiments reveal that the crack growth rate is dependent on the degree of microstructural heterogeneity. This work demonstrates that the crack growth resistance can be tailored within a component using electron beam melting additive manufacturing.

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Acknowledgements

This research was sponsored by the US Department of Energy, Office of Energy Efficiency and Renewable Energy (EERE), Advanced Manufacturing Office under contract DE-AC05-00OR22725 with UT-Battelle LLC and performed in partiality at the Oak Ridge National Laboratory’s Manufacturing Demonstration Facility, an Office of Energy Efficiency and Renewable Energy user facility.

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Authors and Affiliations

  1. Manufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN, United States

    Patxi Fernandez-Zelaia, Julio Ortega Rojas & Michael M. Kirka

  2. Microsoft, Redmond, WA, United States

    James Ferguson

  3. Materials Science & Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, United States

    Sebastien Dryepondt

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  1. Patxi Fernandez-Zelaia
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  2. Julio Ortega Rojas
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Correspondence to Patxi Fernandez-Zelaia.

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Notice of Copyright. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, world-wide license to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan)

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Fernandez-Zelaia, P., Rojas, J.O., Ferguson, J. et al. Fatigue crack growth resistance of a mesoscale composite microstructure Haynes 282 fabricated via electron beam melting additive manufacturing. J Mater Sci 57, 9866–9884 (2022). https://doi.org/10.1007/s10853-021-06838-6

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