Effects of defects on the high-temperature performance of selective laser melting K418 superalloys: An in-situ 3D X-ray analysis

Defects are inevitable in selective laser melting process, significantly impacting the mechanical properties of materials and reducing their service life. In this study, the effects of various defects and their distribution on the high-temperature mechanical performance of the selective laser melted K418 superalloys were investigated via an in-situ 3D X-ray analysis and finite element method. The results showed that the selective laser melting process can significantly enhance the strength of the K418 sample, while degrading the fracture elongation. The sphericity and location of defects are the two key parameters influencing the mechanical performance. The defects with low sphericity at the sub-surface resulted in elevated local stress and strain, accounting for the significant degradation in fracture elongation. Locally increased stress and accumulated strain around lack of fusion defects at the sub-surface contribute to the initiation and propagation of crack. This study provides inspiration for understanding the correlation between the defects and mechanical properties.