On the transferability of post-processing heat treatments designed for PBF-LB IN718 alloys to directed energy deposition specimens

Abstract Many processes are being developed for metal additive manufacturing (AM) which vary by their heat source and feedstock. The use of directed energy deposition (DED) is growing due to its ability to build larger structures outside of a contained powder bed chamber. However, the only standard exclusively for post-build heat treatment of AM IN718 is ASTM standard F3055-14a, developed for powder bed fusion (PBF). This study evaluates the applicability of this current heat treatment standard to AM IN718 specimens produced using two methods of DED: laser-blown powder (LP)-DED and arc-wire (AW)-DED. Electron microscopy and X-ray diffraction techniques were used to characterize the specimens in the as-built condition and after the full heat treatment (FHT) specified in F3055. No evidence of remaining Laves phase was observed in the two DED specimens after the FHT. Yield strengths for the DED specimens were 1049 MPa for FHT AW-DED and 1096 MPa for LP-DED, higher than the minimum stated for PBF-LB IN718 of 920 MPa. The size, morphology, inter-spacing, and diffraction patterns of the γ´ and γ´´ strengthening precipitates are found to be similar for both DED processes. Differences were observed in the microstructure evolution where the F3055 heat treatments resulted in partial recrystallization of the grain structure, with a higher content of annealing twins observed in the AW-DED. These microstructural differences correlate with differences in the resulting elongation to failure. Thus, it is proposed that variations in heat treatments are needed for optimizing IN718 produced by different AM processes.