About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Phase Transformations and Microstructural Evolution
|
| Presentation Title |
Size and Geometry Effects on Cracking and Microstructure in LPBF of Rene 41 Superalloy |
| Author(s) |
Sila E. Atabay, Fatih Sikan, Mathieu Brochu |
| On-Site Speaker (Planned) |
Sila E. Atabay |
| Abstract Scope |
This study systematically investigates the influence of part size and geometry on microstructural evolution and cracking susceptibility in laser powder bed fusion (LPBF) of Rene41 superalloy. Four distinct geometries, incorporating various thicknesses and inclination angles, were fabricated using identical processing conditions to isolate geometric effects. Each component was characterized and compared in terms of dimensional accuracy, crack density and microstructure. Cracks were confined to parts with fine cross-sections and were localized in interdendritic regions. Macro- and micro-scale thermal finite element models were developed and validated against experimental observations, revealing geometry-dependent heat transfer variations that drive microstructural differences. Microhardness measurements correlated with local cooling rates and carbide coarsening. This work highlights the critical role of geometry-specific thermal history in defect formation and emphasizes the need for tailored LPBF process parameters. The findings offer practical insights into the defect-free fabrication of complex, high-performance aerospace components.
Prepared by LLNL under Contract DE-AC52-07NA27344. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Phase Transformations, High-Temperature Materials |