A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuations
The process of electron beam powder bed fusion (PBF-EB) is recognised for its efficacy in preparing non-weldable nickel-based superalloys, leveraging high-temperature preheating to minimise stress-related issues. Traditionally, the PBF-EB process involves pausing the preheating scan during printing...
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2025.2518615 |
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| author | Yang Li Hongyu Long Yurong Wang Bo Wei Yuemei Tan Jun Zhou Xiaoyu Liang Lei Zhang Feng Lin |
| author_facet | Yang Li Hongyu Long Yurong Wang Bo Wei Yuemei Tan Jun Zhou Xiaoyu Liang Lei Zhang Feng Lin |
| author_sort | Yang Li |
| collection | DOAJ |
| description | The process of electron beam powder bed fusion (PBF-EB) is recognised for its efficacy in preparing non-weldable nickel-based superalloys, leveraging high-temperature preheating to minimise stress-related issues. Traditionally, the PBF-EB process involves pausing the preheating scan during printing phases when only one electron gun is available, leading to significant temperature fluctuations and hot cracking during the solidification of these alloys. To address the challenge of fabricating complex parts from such materials, a novel concurrent preheating electron beam powder bed fusion (CPPBF-EB) process employing dual-electron guns has been introduced. An in-depth analysis was conducted on the crack mechanisms of PBF-EBed nickel-based superalloys. Thermal oscillations inherent to the conventional electron beam powder bed fusion (CVPBF-EB) process synergistically induce three pivotal mechanisms in IN738LC superalloys: non-equilibrium carbide precipitation, destabilisation of the γ′ strengthening phase, and stress-mediated dislocation accumulation. These coupled phenomena arise from dynamic thermal gradients during cyclic reheating, which amplify interfacial stress concentrations and enable dislocation penetration through γ′ precipitates, ultimately initiating microcrack formation at geometric heterogeneities. Crucially, we demonstrate that implementing secondary electron beam thermal stabilisation effectively suppresses deleterious phase evolution and defect generation. This breakthrough highlights thermal field modulation as a pivotal control parameter for defect-resistant additive manufacturing of precipitation-strengthened alloys. |
| format | Article |
| id | doaj-art-2eaa25f5e21e488babc808cb76e1ac51 |
| institution | OA Journals |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-2eaa25f5e21e488babc808cb76e1ac512025-08-20T02:37:21ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2025.2518615A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuationsYang Li0Hongyu Long1Yurong Wang2Bo Wei3Yuemei Tan4Jun Zhou5Xiaoyu Liang6Lei Zhang7Feng Lin8Department of Mechanical Engineering, Tsinghua University, Beijing, People’s Republic of ChinaDepartment of Mechanical Engineering, Tsinghua University, Beijing, People’s Republic of ChinaSchool of Mechanical Engineering, Sichuan University, Chengdu, People’s Republic of ChinaDepartment of Mechanical Engineering, Tsinghua University, Beijing, People’s Republic of ChinaDepartment of Mechanical Engineering, Tsinghua University, Beijing, People’s Republic of ChinaInstitute of Laser Intelligent Manufacturing and Precision Processing, School of Mechanical Engineering, Guangxi University, Nanning, People’s Republic of ChinaDepartment of Mechanical Engineering, Tsinghua University, Beijing, People’s Republic of ChinaDepartment of Mechanical Engineering, Tsinghua University, Beijing, People’s Republic of ChinaDepartment of Mechanical Engineering, Tsinghua University, Beijing, People’s Republic of ChinaThe process of electron beam powder bed fusion (PBF-EB) is recognised for its efficacy in preparing non-weldable nickel-based superalloys, leveraging high-temperature preheating to minimise stress-related issues. Traditionally, the PBF-EB process involves pausing the preheating scan during printing phases when only one electron gun is available, leading to significant temperature fluctuations and hot cracking during the solidification of these alloys. To address the challenge of fabricating complex parts from such materials, a novel concurrent preheating electron beam powder bed fusion (CPPBF-EB) process employing dual-electron guns has been introduced. An in-depth analysis was conducted on the crack mechanisms of PBF-EBed nickel-based superalloys. Thermal oscillations inherent to the conventional electron beam powder bed fusion (CVPBF-EB) process synergistically induce three pivotal mechanisms in IN738LC superalloys: non-equilibrium carbide precipitation, destabilisation of the γ′ strengthening phase, and stress-mediated dislocation accumulation. These coupled phenomena arise from dynamic thermal gradients during cyclic reheating, which amplify interfacial stress concentrations and enable dislocation penetration through γ′ precipitates, ultimately initiating microcrack formation at geometric heterogeneities. Crucially, we demonstrate that implementing secondary electron beam thermal stabilisation effectively suppresses deleterious phase evolution and defect generation. This breakthrough highlights thermal field modulation as a pivotal control parameter for defect-resistant additive manufacturing of precipitation-strengthened alloys.https://www.tandfonline.com/doi/10.1080/17452759.2025.2518615Additive manufacturingelectron beam powder bed fusionnon-weldable nickel-based superalloyscrack behavioursconcurrent preheating |
| spellingShingle | Yang Li Hongyu Long Yurong Wang Bo Wei Yuemei Tan Jun Zhou Xiaoyu Liang Lei Zhang Feng Lin A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuations Virtual and Physical Prototyping Additive manufacturing electron beam powder bed fusion non-weldable nickel-based superalloys crack behaviours concurrent preheating |
| title | A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuations |
| title_full | A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuations |
| title_fullStr | A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuations |
| title_full_unstemmed | A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuations |
| title_short | A novel and high-efficiency dual-electron gun concurrent preheating additive manufacturing technology: suppressing thermal cracks in non-weldable IN738LC nickel-based superalloy by mitigating temperature fluctuations |
| title_sort | novel and high efficiency dual electron gun concurrent preheating additive manufacturing technology suppressing thermal cracks in non weldable in738lc nickel based superalloy by mitigating temperature fluctuations |
| topic | Additive manufacturing electron beam powder bed fusion non-weldable nickel-based superalloys crack behaviours concurrent preheating |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2025.2518615 |
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