In situ high-speed milling and thermal post-processing for the optimization of fatigue behaviour of additive-manufactured IN718 components
Source abstract
Abstract
Abstract We report on the optimization of tensile properties and fatigue behaviour of Laser Powder Bed Fusion (PBF-LB/M)-built IN718 components employing an innovative hybrid additive-subtractive technology and various heat treatments. The hybrid approach comprises PBF-LB/M with in situ high-speed milling. Double Ageing, solution and ageing treatment, as well as Hot Isostatic Pressing are used to improve ultimate tensile strength and endurance limit. As a result, the advantages of the hybrid-machined components are clearly demonstrated by their improved mechanical properties. These enhanced properties are associated to changes in microstructure, which are identified as precipitations of IN718. Furthermore, crack initiation and crack growth for high cycle numbers as well as sudden fractures are determined. The additive-subtractive manufacturing approach significantly improves the surface quality with the surface roughness being reduced to $$R_\text {a}$$ < 1 $$\upmu$$m. Superficial cracks and melting errors are excluded by this innovative hybrid approach, contributing to the improved mechanical properties. Graphical abstract
Source: crossref · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Manufacturing Process and Optimization
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (51)
Show source-provided references
1. J. Gardan, Additive manufacturing technologies: state of the art and trends. Int. J. Prod. Res. 54(10), 3118–3132 (2016). https://doi.org/10.1080/00207543.2015.111590910.1080/00207543.2015.1115909 ↗
2. B. Adelmann, T. Schwiddessen, B. Götzendorfer, R. Hellmann, Evaluation of SLS 3D-printed filter structures based on bionic manta structures. Materials (Basel, Switzerland) 15(23), 8454 (2022). https://doi.org/10.3390/ma1523845410.3390/ma15238454 ↗
3. B. Goetzendorfer, H. Kirchgaessner, R. Hellmann, Tunable, anisotropic permeability and spatial flow of SLM manufactured structures. Materials (Basel, Switzerland) 14(18), 5205 (2021). https://doi.org/10.3390/ma1418520510.3390/ma14185205 ↗
4. M.K. Thompson, G. Moroni, T. Vaneker, G. Fadel, I. Campbell, I. Gibson, A. Bernard, J. Schulz, P. Graf, B. Ahuja, Design for additive manufacturing: trends, opportunities, considerations, and constraints. CIRP Ann. 65(2), 737–760 (2016). https://doi.org/10.1016/j.cirp.2016.05.00410.1016/j.cirp.2016.05.004 ↗
5. Z.-C. Fang, Z.-L. Wu, C.-G. Huang, C.-W. Wu, Review on residual stress in selective laser melting additive manufacturing of alloy parts. Optics Laser Technol. 129, 106283 (2020). https://doi.org/10.1016/j.optlastec.2020.10628310.1016/j.optlastec.2020.106283 ↗
6. A.E. Patterson, S.L. Messimer, P.A. Farrington, Overhanging features and the SLM/DMLS residual stresses problem: review and future research need. Technologies 5(2), 15 (2017). https://doi.org/10.3390/technologies502001510.3390/technologies5020015 ↗
7. M. Seabra, J. Azevedo, A. Araújo, L. Reis, E. Pinto, N. Alves, R. Santos, J. Pedro Mortágua, Selective laser melting (SLM) and topology optimization for lighter aerospace componentes. Proc. Struct. Integr. 1, 289–296 (2016). https://doi.org/10.1016/j.prostr.2016.02.03910.1016/j.prostr.2016.02.039 ↗
8. A. Fortunato, A. Lulaj, S. Melkote, E. Liverani, A. Ascari, D. Umbrello, Milling of maraging steel components produced by selective laser melting. Int. J. Adv. Manuf. Technol. 94(5), 1895–1902 (2018). https://doi.org/10.1007/s00170-017-0922-910.1007/s00170-017-0922-9 ↗
9. A. Matras, Research and optimization of surface roughness in milling of SLM semi-finished parts manufactured by using the different laser scanning speed. Materials 13(1), 9 (2019). https://doi.org/10.3390/ma1301000910.3390/ma13010009 ↗
10. M. Merklein, D. Junker, A. Schaub, F. Neubauer, Hybrid additive manufacturing technologies—an analysis regarding potentials and applications. Phys. Proc. 83, 549–559 (2016). https://doi.org/10.1016/j.phpro.2016.08.05710.1016/j.phpro.2016.08.057 ↗
11. M.A. Rahman, T. Saleh, M.P. Jahan, C. McGarry, A. Chaudhari, R. Huang, M. Tauhiduzzaman, A. Ahmed, A.A. Mahmud, M.S. Bhuiyan, M.F. Khan, M.S. Alam, M.S. Shakur, Review of intelligence for additive and subtractive manufacturing: current status and future prospects. Micromachines 14(3), 508 (2023). https://doi.org/10.3390/mi1403050810.3390/mi14030508 ↗
12. K.P. Karunakaran, S. Suryakumar, V. Pushpa, S. Akula, Low cost integration of additive and subtractive processes for hybrid layered manufacturing. Robot. Comput. Integr. Manuf. 26(5), 490–499 (2010). https://doi.org/10.1016/j.rcim.2010.03.00810.1016/j.rcim.2010.03.008 ↗
13. P. Wüst, A. Edelmann, R. Hellmann, Areal surface roughness optimization of maraging steel parts produced by hybrid additive manufacturing. Materials 13(2), 418 (2020). https://doi.org/10.3390/ma1302041810.3390/ma13020418 ↗
14. S. Sarafan, P. Wanjara, R. Pelletier, S.E. Atabay, J. Gholipour, J. Soost, R. Amos, P. Patnaik, Elevated-temperature tensile behavior and properties of Inconel 718 fabricated by in-envelope additive-subtractive hybrid manufacturing and post-process precipitation hardening. J. Manuf. Mater. Process. 8(6), 297 (2024). https://doi.org/10.3390/jmmp806029710.3390/jmmp8060297 ↗
15. D. Sommer, B. Götzendorfer, C. Esen, R. Hellmann, Design rules for hybrid additive manufacturing combining selective laser melting and micromilling. Materials 14(19), 5753 (2021). https://doi.org/10.3390/ma1419575310.3390/ma14195753 ↗
16. S. Sarafan, P. Wanjara, J. Gholipour, F. Bernier, M. Osman, F. Sikan, M. Molavi-Zarandi, J. Soost, M. Brochu, Evaluation of maraging steel produced using hybrid additive/subtractive manufacturing. J. Manuf. Mater. Process. 5(4), 107 (2021). https://doi.org/10.3390/jmmp504010710.3390/jmmp5040107 ↗
17. D. Sommer, S. Hornung, C. Esen, R. Hellmann, Design guide for hybrid-additive manufacturing of Inconel 718 combining PBF-LB/M and in situ high-speed milling. J. Manuf. Mater. Process. 9(3), 88 (2025). https://doi.org/10.3390/jmmp903008810.3390/jmmp9030088 ↗
18. C. Pei, D. Shi, H. Yuan, H. Li, Assessment of mechanical properties and fatigue performance of a selective laser melted nickel-base superalloy Inconel 718. Mater. Sci. Eng., A 759, 278–287 (2019). https://doi.org/10.1016/j.msea.2019.05.00710.1016/j.msea.2019.05.007 ↗
19. A.V. Sotov, A.V. Agapovichev, V.G. Smelov, V.V. Kokareva, M.O. Dmitrieva, A.A. Melnikov, S.P. Golanov, Y.M. Anurov, Investigation of the IN-738 superalloy microstructure and mechanical properties for the manufacturing of gas turbine engine nozzle guide vane by selective laser melting. Int. J. Adv. Manuf. Technol. 107(5–6), 2525–2535 (2020). https://doi.org/10.1007/s00170-020-05197-x10.1007/s00170-020-05197-x ↗
20. A.K. Maurya, A. Kumar (2021) Study of microstructure and mechanical properties of as-built and heat-treated additive manufactured Inconel 718 alloy. ASEAN J. Sci. Technol. Develop. https://doi.org/10.29037/ajstd.72410.29037/ajstd.724 ↗
21. A.A. Popovich, V.S. Sufiiarov, I.A. Polozov, E.V. Borisov, Microstructure and mechanical properties of inconel 718 produced by SLM and subsequent heat treatment. Mater. Form. ESAFORM 2015(651–653), 665–670 (2015). https://doi.org/10.4028/www.scientific.net/KEM.651-653.66510.4028/www.scientific.net/KEM.651-653.665 ↗
22. L. Zhang, X. Shi, N. Li, L. Zhao, W. Chen, Heterogeneities of microstructure and mechanical properties for Inconel 718 strut tensile sample fabricated by selective laser melting. J. Market. Res. 12, 2396–2406 (2021). https://doi.org/10.1016/j.jmrt.2021.04.02910.1016/j.jmrt.2021.04.029 ↗
23. D. Zhang, Z. Feng, C. Wang, W. Wang, Z. Liu, W. Niu, Comparison of microstructures and mechanical properties of Inconel 718 alloy processed by selective laser melting and casting. Mater. Sci. Eng., A 724, 357–367 (2018). https://doi.org/10.1016/j.msea.2018.03.07310.1016/j.msea.2018.03.073 ↗
24. A. Sukumaran, R.K. Gupta, V. Anil Kumar, Effect of heat treatment parameters on the microstructure and properties of Inconel-625 superalloy. J. Mater. Eng. Perform. 26(7), 3048–3057 (2017). https://doi.org/10.1007/s11665-017-2774-810.1007/s11665-017-2774-8 ↗
25. M. Calandri, D. Manfredi, F. Calignano, E.P. Ambrosio, S. Biamino, R. Lupoi, D. Ugues, Solution treatment study of Inconel 718 produced by SLM additive technique in view of the oxidation resistance. Adv. Eng. Mater. 20(11), 1800351 (2018). https://doi.org/10.1002/adem.20180035110.1002/adem.201800351 ↗
26. S. Sarkar, C.S. Kumar, A.K. Nath, Effects of different surface modifications on the fatigue life of selective laser melted 15–5 PH stainless steel. Mater. Sci. Eng., A 762, 138109 (2019). https://doi.org/10.1016/j.msea.2019.13810910.1016/j.msea.2019.138109 ↗
27. A. Dareh Baghi, S. Nafisi, R. Hashemi, H. Ebendorff-Heidepriem, R. Ghomashchi, Experimental realisation of build orientation effects on the mechanical properties of truly as-built Ti-6Al-4V SLM parts. J. Manuf. Process. 64, 140–152 (2021). https://doi.org/10.1016/j.jmapro.2021.01.02710.1016/j.jmapro.2021.01.027 ↗
28. L. Liu, P. Kamm, F. García-Moreno, J. Banhart, D. Pasini, Elastic and failure response of imperfect three-dimensional metallic lattices: the role of geometric defects induced by Selective Laser Melting. J. Mech. Phys. Solids 107, 160–184 (2017). https://doi.org/10.1016/j.jmps.2017.07.00310.1016/j.jmps.2017.07.003 ↗
29. A.K. Sahu, S. Bag, Design of a double aging treatment for the improvement of mechanical and microstructural properties of pulse micro-plasma arc welded alloy 718. J. Mater. Sci. 56(23), 13400–13415 (2021). https://doi.org/10.1007/s10853-021-06121-810.1007/s10853-021-06121-8 ↗
30. M.E. Aydinöz, F. Brenne, M. Schaper, C. Schaak, W. Tillmann, J. Nellesen, T. Niendorf, On the microstructural and mechanical properties of post-treated additively manufactured Inconel 718 superalloy under quasi-static and cyclic loading. Mater. Sci. Eng., A 669, 246–258 (2016). https://doi.org/10.1016/j.msea.2016.05.08910.1016/j.msea.2016.05.089 ↗
31. H. Yuan, W.C. Liu, Effect of the delta-phase on the hot deformation behavior of Inconel 718. Mater. Sci. Eng., A 408(1–2), 281–289 (2005). https://doi.org/10.1016/j.msea.2005.08.12610.1016/j.msea.2005.08.126 ↗
32. S. Raghavan, B. Zhang, P. Wang, C.-N. Sun, M. Nai, T. Li, J. Wei, Effect of different heat treatments on the microstructure and mechanical properties in selective laser melted INCONEL 718 alloy. Mater. Manuf. Processes 32(14), 1588–1595 (2017). https://doi.org/10.1080/10426914.2016.125780510.1080/10426914.2016.1257805 ↗
33. Y. Gao, D. Zhang, M. Cao, R. Chen, Z. Feng, R. Poprawe, J.H. Schleifenbaum, S. Ziegler, Effect of delta phase on high temperature mechanical performances of Inconel 718 fabricated with SLM process. Mater. Sci. Eng., A 767, 138327 (2019). https://doi.org/10.1016/j.msea.2019.13832710.1016/j.msea.2019.138327 ↗
34. H. Qi, M. Azer, A. Ritter, Studies of standard heat treatment effects on microstructure and mechanical properties of laser net shape manufactured Inconel 718. Metall. Mater. Trans. A 40(10), 2410–2422 (2009). https://doi.org/10.1007/s11661-009-9949-310.1007/s11661-009-9949-3 ↗
35. E. Chlebus, K. Gruber, B. Kuźnicka, J. Kurzac, T. Kurzynowski, Effect of heat treatment on the microstructure and mechanical properties of Inconel 718 processed by selective laser melting. Mater. Sci. Eng., A 639, 647–655 (2015). https://doi.org/10.1016/j.msea.2015.05.03510.1016/j.msea.2015.05.035 ↗
36. J.J. Rindler, C.E. Slone, E.D. Herderick, M.J. Mills, A.J. Ramirez, Investigation on the potential effects of laser stitching and subsequent heat treatment on the microstructure and mechanical properties of Nickel Alloy 718 produced via Laser Powder Bed Fusion (L-PBF). Addit. Manuf. 57, 102906 (2022). https://doi.org/10.1016/j.addma.2022.10290610.1016/j.addma.2022.102906 ↗
37. R. Konečná, G. Nicoletto, L. Kunz, A. Bača, Microstructure and directional fatigue behavior of Inconel 718 produced by selective laser melting. Proc. Struct. Integr. 2, 2381–2388 (2016). https://doi.org/10.1016/j.prostr.2016.06.29810.1016/j.prostr.2016.06.298 ↗
38. C. Yu, Z. Huang, Z. Zhang, J. Shen, J. Wang, Z. Xu, Influence of post-processing on very high cycle fatigue resistance of Inconel 718 obtained with laser powder bed fusion. Int. J. Fatigue 153, 106510 (2021). https://doi.org/10.1016/j.ijfatigue.2021.10651010.1016/j.ijfatigue.2021.106510 ↗
39. F. Liu, T. Zhou, T. Zhang, H. Xie, Y. Tang, P. Zhang, Shell offset enhances mechanical and energy absorption properties of SLM-made lattices with controllable separated voids. Mater. Des. 217, 110630 (2022). https://doi.org/10.1016/j.matdes.2022.11063010.1016/j.matdes.2022.110630 ↗
40. E. Hosseini, V.A. Popovich, A review of mechanical properties of additively manufactured Inconel 718. Addit. Manuf. 30, 100877 (2019). https://doi.org/10.1016/j.addma.2019.10087710.1016/j.addma.2019.100877 ↗
41. H. Zhang, J. Dang, W. Ming, X. Xu, M. Chen, Q. An, Cutting responses of additive manufactured Ti6Al4V with solid ceramic tool under dry high-speed milling processes. Ceram. Int. 46(10), 14536–14547 (2020). https://doi.org/10.1016/j.ceramint.2020.02.25310.1016/j.ceramint.2020.02.253 ↗
42. A.N. Soe, A. Sombatmai, P. Promoppatum, V. Srimaneepong, V. Trachoo, P. Pandee, Effect of post-processing treatments on surface roughness and mechanical properties of laser powder bed fusion of Ti-6Al-4V. J. Market. Res. 32, 3788–3803 (2024). https://doi.org/10.1016/j.jmrt.2024.08.19710.1016/j.jmrt.2024.08.197 ↗
43. J. Diller, J. Blankenhagen, D. Siebert, C. Radlbeck, M. Mensinger, Combined effect of surface treatment and heat treatment on the fatigue properties of AISI 316L, manufactured by powder bed fusion of metals using a laser (PBF-LB/M). Int. J. Fatigue 178, 108025 (2024). https://doi.org/10.1016/j.ijfatigue.2023.10802510.1016/j.ijfatigue.2023.108025 ↗
44. D. Ordnung, T. Mertens, J. Tacq, M.H. Nasab, M. Sinico, G. Li, L. Thijs, B. Vrancken, B. van Hooreweder, Enhancing fatigue life of as-printed martensitic M789 steel produced by laser powder bed fusion via in-process surface integrity improvement and phase change induced compressive residual stresses. Addit. Manuf. 88, 104263 (2024). https://doi.org/10.1016/j.addma.2024.10426310.1016/j.addma.2024.104263 ↗
45. C. Meier, R.W. Penny, Y. Zou, J.S. Gibbs, A.J. Hart, Thermophysical phenomena in metal additive manufacturing by selective laser melting: fundamentals, modeling, simulation and experimentation. Ann. Rev. Heat Transfer 20(1), 241–316 (2017). https://doi.org/10.1615/AnnualRevHeatTransfer.201801904210.1615/AnnualRevHeatTransfer.2018019042 ↗
46. A. Amanov, R. Karimbaev, E. Maleki, O. Unal, Y.-S. Pyun, T. Amanov, Effect of combined shot peening and ultrasonic nanocrystal surface modification processes on the fatigue performance of AISI 304. Surf. Coat. Technol. 358, 695–705 (2019). https://doi.org/10.1016/j.surfcoat.2018.11.10010.1016/j.surfcoat.2018.11.100 ↗
47. C. Yu, Z. Huang, Z. Zhang, J. Wang, J. Shen, Z. Xu, Effects of sandblasting and HIP on very high cycle fatigue performance of SLM-fabricated IN718 superalloy. J. Market. Res. 18, 29–43 (2022). https://doi.org/10.1016/j.jmrt.2022.02.07710.1016/j.jmrt.2022.02.077 ↗
48. D. Sommer, S. Hornung, C. Esen, R. Hellmann, Surface roughness optimization of hybrid PBF-LB/M-built Inconel 718 using in situ high-speed milling. Int. J. Adv. Manuf. Technol. 132(3–4), 1741–1751 (2024). https://doi.org/10.1007/s00170-024-13382-510.1007/s00170-024-13382-5 ↗
49. D. Sommer, D. Pape, C. Esen, R. Hellmann, Tool wear and milling characteristics for hybrid additive manufacturing combining laser powder bed fusion and in situ high-speed milling. Materials 15(3), 1236 (2022). https://doi.org/10.3390/ma1503123610.3390/ma15031236 ↗
50. D. Sommer, A. Safi, C. Esen, R. Hellmann, Additive manufacturing of Nickel-based superalloy: optimization of surface roughness using integrated high-speed milling. Proc. SPIE 12876 Laser 3D Manuf. XI 10(1117/12), 3000972 (2024). https://doi.org/10.1117/12.300097210.1117/12.3000972 ↗
51. G. Petzow, Metallographic etching: techniques for metallotraphy, ceramography, plastography, 2. ed., 1. print edn. ASM International, Materials Park, Ohio (1999).