Abstract
Complex geometries and topology optimisations for weight and materials savings are leading drivers for the additive manufacturing of Ni-based superalloys through electron beam powder bed fusion (PBF-EB). However, there is a marked departure in these geometrically complex components with respect to the thermal signatures understood in commonly studied prismatic PBF-EB test coupons. This often results in unaccounted site-specific microstructure-property variations in complex PBF-EB builds. Here, the effects of topological changes, such as intentionally engineered internal voids, on the mechanical performance of an as-fabricated Haynes 282 monolith is revealed. The internal voids serve as representative physical models for changing thermal boundary conditions with build height. Complementary local nanoindentations, multi-scale microscopy, and residual stress measurements were used to understand the mechanisms behind geometry-structure-property relationships. The results highlight the effectiveness and influence of changing thermal conditions on the local mechanical property response of PBF-EB Haynes 282.
