Welding Heat-induced Microstructural Variations in Inconel 718 Superalloy: A Comparative Investigation between Conventionally Manufactured and 3D Printed Materials

Abstract

This study focuses on the microstructural evolution of Inconel 718 superalloy, a precipitation-hardened superalloy, subjected to various manufacturing processes and subsequent thermal exposures. Conventional manufacturing methods such as casting and forging were compared with modern 3D printing techniques, notably wire-arc additive manufacturing. Subsequent treatments, including solution treatment and two-stage aging, as well as bead-on-plate welding, were performed to assess their effects on the microstructure of Inconel 718. The transformations of strengthening phases such as γ′(Ni3(Al,Ti)), γ″(Ni3Nb) and intermetallic δ(Ni3Nb) phases were observed to vary significantly under different thermal cycles, and these variations in phase transformation are anticipated to lead to a degradation in mechanical performance post-welding. Additionally, thermodynamic calculations using commercial Calphad software were utilized to investigate phase transformations in the welds, providing critical insights into how manufacturing processes and thermal exposures affect the stability and distribution of microstructural features, thereby highlighting the complexities of phase dynamics in this high-performance alloy.