Properties of Electrode Induction Melting Gas Atomization- and Vacuum Induction Melting Atomization-Produced Powders and Their As-HIPed Blanks

The main method for large-scaled preparing powder superalloys in the production process is inert gas atomization, particularly vacuum-induced gas atomization (VIGA). A novel technique called electrode-induced gas atomization (EIGA) with a crucible-free electrode was proposed to prepare non-inclusion superalloy powders. In this study, a Ni-based superalloy of FGH4096 powder was prepared using both the VIGA and EIGA methods, while blanks were prepared through direct hot isostatic pressing (as-HIPed) near-net-forming method. The particle size, morphology, microstructure, and mechanical properties of the powders and blanks were compared via a laser particle size analyzer, SEM, TEM, and room-temperature and 650 °C tensile tests. The results indicated that EIGA-prepared powders exhibited a finer particle size and better surface quality than the one prepared via VIGA, which showed reduced satellite powders. However, the as-HIPed blank of EIGA-prepared powders had a lower secondary γ' ratio and slightly reduced strength compared to the as-HIPed blank of VIGA-prepared powders due to its slightly lower secondary γ' phase ratio and less effective inhibition of dislocation movement. Furthermore, the overall performance of the two samples did not differ significantly due to the similar microstructural characteristics of the powders. However, the variation in particle size affects heat conduction during the HIP process, resulting in slight differences in blanks' properties.