2Ford Otosan Ihsaniye Automotive Vocational School, Kocaeli University, Kocaeli, Türkiye
3R&D Department, Ermaksan, Bursa, Türkiye
Abstract
Additive manufacturing (AM) is a state-of-the-art technique that enables the production of advanced materials with complex designs. Nonetheless, many challenges remain in the additive manufacturing of nickel-based superalloy components, especially in revealing the effects of processing parameters on their microstructural characteristics. The present study aims to reveal the effect of laser energy density (LED) on porosity and microstructural features of the Inconel 625 (IN625) alloy produced by SLM using a newly developed SLM metal additive manufacturing machine (ENAVISION 250, Ermaksan, Türkiye) for the first time. The layer thickness was selected as 30 µm for all samples. The samples were produced with 9 different LED values (ranging between 0.78 and 2.80 J/mm) using a 350 W laser power and scanning speeds ranging from 125 to 450 mm.s-1. Optical microscope images of the polished and etched samples in the XY, XZ, and XY planes were studied. The influence of the LED intensity on both the quantity and morphology of the pores in the structure was evaluated. Spherical-shaped pores were identified in samples with LED levels of 1 J/mm and above. The porosities within the structure increased after the LED value attained 1.17 J/mm, simultaneously revealing an increase in pore size with the increasing LED value. The application of high energy density to the powders led to an increase in the solubility of gas, resulting in the formation of numerous spherical pores. This study indicated that the optimum LED value for IN625 alloy with a layer thickness of 30 µm is 0.78 J/mm. The study offers significant insights into the correlation between LED value and the microstructural characteristics of superalloys fabricated by SLM, thereby aiding in the optimisation of SLM processing parameters for diverse components across various sectors, including aerospace, aviation, automotive, and defence industries.