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Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Crack Reduction in L-PBF CM247LC using Shell and Core Build Style
Author(s) Satyendra Kutiyal, Ravi Aswathanarayanaswamy, Andrew Moore, Andy Farndell, Nick Jones
On-Site Speaker (Planned) Satyendra Kutiyal
Abstract Scope This study examines crack formation in nickel-based superalloy CM247LC produced by laser powder bed fusion (L-PBF) at 10µm and 20µm layer thicknesses. Reducing to 10µm decreased crack density by 75%, though it increased build time, subsurface regions were crack-free compared to those produced at 20µm. A shell and core approach (20µm core and 10µm shell), improved build rate by 18% and reduced crack by 25% relative to the 20µm layer process. However, remelting at shell-core interfaces caused localised cracking. Scanning Electron Microscopy (SEM) identified ductility dip, solidification, and liquation cracks. Hot Isostatic Pressing (HIP) minimised cracks, and further heat treatments promoted γ′ precipitation. Heat-treated samples exhibited hardness of 452 ± 10 HV0.5, room temperature tensile strength of 1181 ± 56 MPa, and elongation of 11 ± 1%. SEM fracture analysis revealed grain-boundary cracking and brittle fracture. Overall, the shell and core approach enables HIP-ready L-PBF parts without compromising tensile properties.
Proceedings Inclusion? Undecided

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