Microstructure and fatigue behaviour of the additively manufactured CrMnFeCoNi high-entropy alloy
File(s)
Author(s)
Jin, Minsoo
Type
Thesis
Abstract
In this study, two common AM processes – laser powder bed fusion (LPBF) and directed energy deposition (DED) were employed to fabricate CrMnFeCoNi High-Entropy Alloy (HEA). DED print parameters were varied (100 and 200 W, 1.0-2.5 mm/s) to achieve columnar-to-equiaxed transition and more isotropic mechanical behaviour in the AM HEA. In-situ x-ray synchrotron radiography and the Rosenthal solution results showed increasing laser power from 100 W to 200 W resulted in melt-pools with higher volumes. In consequence, lower thermal gradients were generated in the larger melt-pools and favoured the CET. Hence, grain structures with more equiaxed grains were observed in the samples fabricated at a higher laser power. Amongst all the considered conditions, 200 W and 1.5 mm/s was found to be an optimal process condition for the CET. The presence of equiaxed grains in this scan condition resulted in better mechanical properties than those built at different parameters. Fatigue tests were conducted at a range of temperatures (22-600 °C) and two strain rates (10-3 s-1 and 10-2 s-1) to understand fatigue behaviour of the LPBF HEA and its temperature dependence. Fatigue samples were printed with different print strategies (chessboard 67°, meander 90°, and meander 0°) and surface conditions (as-printed and machined) to understand influence of print processes on fatigue performance. Solidification cellular microstructure was present in the LPBF HEA due to a high thermal gradient and cooling rates in AM processes. These cells remained stable throughout fatigue tests as there was no driving force for further microstructure evolution. The fine solidification cells and dislocation networks at cell boundaries restricted dislocation movements, resulting in an improved cyclic yield stress compared to the cast CrMnFeCoNi HEA. As temperature increased, dislocations annihilated and rearranged at a higher rate thanks to thermal assistance. In consequence, the dislocation networks became destroyed and less organised. Thus, cyclic strength of the LPBF samples decreased at elevated temperatures. Print strategy was found insignificant on the fatigue life of the HEA due to the presence of porosity in sub-surface regions of the HEA samples in the as-printed condition. Such porosity predominantly affected the crack initiation, overwhelming the role of the scan strategy. Removal of the porosity by machining the surface improved fatigue lives of the samples.
Version
Open Access
Date Issued
2022-02
Date Awarded
2022-04
Copyright Statement
Creative Commons Attribution NonCommercial NoDerivatives Licence
Advisor
Pham, Minh-Son
Gourlay, Christopher
Publisher Department
Department of Materials
Publisher Institution
Imperial College London
Qualification Level
Doctoral
Qualification Name
Doctor of Philosophy (PhD)