In-situ x-ray synchrotron measurements of EB-PBF manufactured nickel-based superalloys

Important results from the project

The project fulfilled its objectives by providing new, quantitative knowledge on microstructural evolution, precipitation kinetics, and stress development during electron beam powder bed fusion (PBF-EB) of γ′-strengthened Ni-based superalloys. The results clarified important differences between the alloys MAR-M-247 and Haynes 282 and provided a scientific basis for understanding crack formation. The project also contributed to strengthened collaborations and increased international engagement.

Expected long term effects

In the long term, the project is expected to enable a more robust and predictable use of PBF-EB for the manufacturing of γ′-strengthened Ni-based superalloys. The improved understanding of microstructure, stress evolution, and crack formation provides a basis for developing tailored alloys and processes, potentially reducing lead times, material waste, and energy consumption while strengthening competitiveness in the aerospace and gas turbine industries.

Approach and implementation

The project was carried out as planned and followed the schedule. Three partners participated: KTH, GKN Aerospace, and University West, with a postdoctoral researcher leading the day-to-day work. The project included in situ experiments at the P21.2 beamline, PETRA III, at DESY, where two granted beam times were conducted with active participation from industrial representatives. The project generated extensive datasets, meaning that some analyses will continue in subsequent projects.