Limits of dispersoid size and number density in oxide dispersion strengthened alloys fabricated with powder bed fusion-laser beam

• Published in: Additive manufacturing 2024-02, Vol.81, p.104022, Article 104022
• Main Authors: Wassermann, Nathan A., Li, Yongchang, Myers, Alexander J., Kantzos, Christopher A., Smith, Timothy M., Beuth, Jack L., Malen, Jonathan A., Shao, Lin, McGaughey, Alan J.H., Narra, Sneha P.
• Format: Article
• Language: English
• Subjects: High-temperature alloys; MATERIALS SCIENCE; Nickel alloy; Oxide dispersion strengthening (ODS); Oxide evolution; Powder bed fusion
• ISSN: 2214-8604; 2214-7810
• DOI: 10.1016/j.addma.2024.104022

Previous work on additively-manufactured oxide dispersion strengthened alloys focused on experimental approaches, resulting in larger dispersoid sizes and lower number densities than can be achieved with conventional powder metallurgy. To improve the as-fabricated microstructure, this work integrates experiments with a thermodynamic and kinetic modeling framework to probe the limits of the dispersoid sizes and number densities that can be achieved with powder bed fusion-laser beam. Bulk samples of a Ni–20Cr ＋ 1 wt% Y2O3 alloy are fabricated using a range of laser power and scanning velocity combinations. Scanning transmission electron microscopy characterization is performed to quantify the dispersoid size distributions across the processing space. The smallest mean dispersoid diameter (29 nm) is observed at 300 W and 1200 mm/s, with a number density of 1.0 × 1020 m−3. The largest mean diameter (72 nm) is observed at 200 W and 200 mm/s, with a number density of 1.5 × 1019 m−3. Scanning electron microscopy suggests that a considerable fraction of the oxide added to the feedstock is lost during processing, due to oxide agglomeration and the ejection of oxide-rich spatter from the melt pool. After accounting for these losses, the model predictions for the dispersoid diameter and number density align with the experimental trends. The results suggest that the mechanism that limits the final number density is collision coarsening of dispersoids in the melt pool. The modeling framework is leveraged to propose processing strategies to limit dispersoid size and increase number density. [Display omitted] •Bulk samples of a Ni–20Cr ODS alloy are fabricated with powder bed fusion-laser beam.•A model is applied to gain insight into the evolution of oxide dispersoids.•STEM characterization is performed across the processing space for model validation.•Shorter dispersoid residence times yield higher number densities and smaller sizes.•Number density is limited by collision coarsening of dispersoids in the melt pool.