Application of Wire and Electron Beam Additive Manufacturing for Large-Sized Industrial Products

Abstract

This paper focuses on studying the structure formation of large-scale nickel-based alloy and steel samples and compares them with previously obtained data on additive titanium, aluminum, copper, and other alloys. These studies demonstrate that the structural and phase state of nickel-based alloys and steels mainly depends on the alloy type and alloying elements. The longer existence of a melt pool and resulting partitioning of alloying elements for Inconel 625 alloys pose a significant printing challenge, while Inconel 718 alloys and high-alloy nickel-based high temperature alloys exhibit excellent mechanical properties. Furthermore, partitioning of alloying elements along dendrite boundaries can be unavoidable during heat treatment due to the formation of insoluble carbide particles. Printing austenitic stainless steels results in a structure represented by dendritic colonies, while ferrite-pearlite steels are characterized by the formation of a grain structure. Various types of steels and nickel-based alloys, as well as bimetallic components based on them, do not typically exhibit defects such as pores or cracks. A smooth transition zone from one material to another is formed in the structural gradient zone. The obtained data demonstrate that wire and feed electron beam additive manufacturing is one of the most suitable for the manufacture of parts from various types of steels and nickel-based alloys, including bimetallic components based on them.