Prevention of solidification cracking in alloy 718 additive manufacturing by laser metal deposition method based on control guidelines for weld solidification cracking

The chemical composition of alloy 718 powder was optimized to suppress a solidification cracking in the additive manufactured part by the laser metal deposition method. The relationship between the condition of additive manufacturing and defects was evaluated. A lack of fusion was observed on the low heat input (low energy density), and the solidification cracking occurred on the high heat input (high energy density). The powder composition of alloy 718 was attempted to be optimized from a theoretical approach of the solidification cracking susceptibility. It was found that Si and B had a significant influence on the solidification cracking, therefore a preventive powder with reduced Si and B was developed. The effects of Si and B on solidification cracking were compared by reproducing the solidification conditions during additive manufacturing and evaluating the solidification brittle temperature range (BTR) using the Varestraint test. It was found that the BTR of the preventive material was smaller, and the solidification cracking susceptibility was improved. In addition, the solidification cracking did not occur in additive manufacturing using the preventive powder. In other words, it is suggested that the countermeasure for weld solidification cracking leads to the prevention of solidification cracking in additive manufacturing directly, and the effectiveness of the optimization of powder composition was verified.