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Static and Fatigue Properties of Rhenium-Alloyed Inconel 718 Produced by Powder Bed Fusion Additive Manufacturing.

Mariusz Frankiewicz1, Michał Karoluk1, Robert Dziedzic1

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Summary

Coating Inconel 718 powder with rhenium via in situ alloying improved high-temperature elongation, though fatigue was limited by process defects. This demonstrates a flexible approach for tailored nickel-based alloy design in additive manufacturing.

Keywords:
Inconel 718fatigue propertieslaser powder bed fusionmicrostructurerheniumtensile properties

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Area of Science:

  • Materials Science
  • Metallurgy
  • Additive Manufacturing

Background:

  • Inconel 718 (In718) is a widely used nickel-based alloy in additive manufacturing (AM) due to its processability.
  • Its high-temperature performance limits applications in demanding sectors like aerospace.
  • Improving In718's high-temperature properties is crucial for advanced engineering.

Purpose of the Study:

  • To enhance the high-temperature performance of Inconel 718 by incorporating rhenium (Re).
  • To investigate the effects of post-processing treatments on the mechanical properties of rhenium-coated In718.
  • To explore the potential of in situ alloying for tailored nickel-based alloy development in AM.

Main Methods:

  • Inconel 718 powder was surface-coated with 3% wt. rhenium using in situ alloying.
  • Parts were fabricated using laser-based powder bed fusion of metals (PBF-LB/M).
  • Mechanical properties were evaluated through static tensile tests (room temperature, 650 °C, 760 °C) and fatigue tests (room temperature).
  • Post-process heat treatment and hot isostatic pressing were applied.

Main Results:

  • The In718-Re alloy exhibited comparable strength to In718 (UTS: 1247 MPa, YS: 909 MPa) but with significantly higher elongation (23.8%) at room temperature.
  • Fatigue tests at room temperature showed a fatigue limit below 400 MPa for 10^7 cycles.
  • Fractographic analysis identified lack of fusion defects from PBF-LB/M as the primary cause of limited fatigue performance.
  • Rhenium addition showed minimal benefits for Inconel 718 under the tested conditions.

Conclusions:

  • In situ alloying via powder surface modification is a viable method for incorporating elements like rhenium into nickel-based alloys.
  • Optimizing powder preparation and PBF-LB/M parameters is essential to mitigate defects and improve fatigue performance.
  • While direct benefits of Re were limited in this study, the approach offers a flexible route for designing advanced alloys for additive manufacturing.