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Additive layer manufacturing is a blanket term for a wide range of processes operating on the same underlying principle. 3D geometry is created by depositing material, layer by layer to create a final 3D geometry. Selective laser melting (SLM) is a branch of additive layer manufacturing, using a laser to fuse a powder bed of metal into each layer. This thesis investigates the SLM process and its application to nickel based superalloy materials, IN625 and IN718. IN625 and IN718 are similar nickel-based superalloys developed for use in aerospace gas turbine engines. In their conventionally manufactured form, these materials have excellent high temperature mechanical properties which make them idea for use in the hot section of gas turbine engines. The aim of this thesis was to investigate how these materials interact with the SLM process and how the material produced can be optimised to improve the range of applications it can be used for. A gap in knowledge regarding a detailed understanding of how the powders morphological and rheological properties influence its ability to be processed by SLM was identified and investigated. A wide range of characterisation methods were implemented with certain important properties being identified to assess a powders processability, namely the particle size distribution and how a significant content of fine particles below 10 μm in size can be detrimental to processability. There is also a lack of a standard powder characterisation methodology specifically for SLM applications. This is addressed with certain methods and measurements being suggested as most promising for wider SLM application. Avalanche flow testing is found to be most applicable to the critical recoating process in SLM and most able to differentiate suitable and unsuitable SLM powders. Following characterisation of the raw material feedstock powder, this thesis also investigates the influence of processing parameters on the microstructure of the material produced by the SLM process. Significant microstructural changes were observed as a result of process parameter changes. This was identified to potentially enable for in-situ modification of material microstructure to suit a manufactured material to its end application. Of the process parameters investigated, laser scan speed was most interesting, suggesting that a faster laser scan speed was able to create a similar microstructure to a much slower one. This was attributed to the reheating effect of the laser beam returning quickly to the adjacent scan line. The validity of this explanation was investigated using a simple, computational thermal model. The result is a new understanding of laser scan speed SLM and its nonlinear relationship with material temperature and microstructure evolution. Finally, post process heat treatments of SLM manufactured IN718 material were investigated. This investigation was in response to a gap in current knowledge regarding heat treatments designed specifically for SLM material. SLM IN718 has been found to have reduced high temperature mechanical properties, specifically stress rupture, which limits its application in demanding environments. In this thesis a range of post process homogenisation heat treatments were investigated, with treatments between 1030 °C and 1060 °C being found to produce material with characteristics consistent with material with excellent stress rupture properties. This novel heat treatment route could provide a method for SLM IM718, and the increased design and geometric freedoms, to be applied in more demanding applications. An evolution of the grain structure in the material was also observed and measured during high temperature homogenisation treatments. This was investigated in the final chapter, and a novel mechanism is suggested for the process of grain coarsening observed. Previously published literature explains similar evolutions as recrystallisation however this did not fit the observations during this thesis. The evolution of grain structure was observed using a process of quasi in-situ electron back scatter diffraction, and a mechanism of grain boundary length reduction, followed by grain growth, is suggested to better fit the observations. It was determined that grains are preferentially selected for growth based on their proximity to a ‘path of least resistance’ of lower angle grain boundaries. The results of this work should benefit industrial users of SLM in the fabrication of Nickel-Based Superalloy material for aerospace applications. The conclusions on powder characterisation offer an insight into available methods to better control and characterise powder feedstock materials for consistent production. Aerospace users especially may find the work regarding post process heat treatments designed specifically for SLM material, to recover lost stress rupture performance, useful in enabling the use of SLM materials, and the design freedom that brings with it, in mor demanding environments than are currently possible.

Powder Characterisation, Microstructure, and Mechanical Property Evolution of IN625 and IN718 During Selective Laser Melting and Heat Treatment