Influence of laser beam shape and post heat-treatment on the microstructure and mechanical properties of nickel-based alloy IN718 manufactured by laser powder bed fusion

This study examines the effect of Gaussian and ring-shaped laser beam profiles on the microstructural development and mechanical properties of the PBF-LB/M processed nickel-based alloy Inconel 718 in its as-built and post-heat-treated conditions. Beam shaping was employed to achieve a faster build rate without compromising material properties. One of the objectives was to optimise heat treatment conditions for the beam-shaped profile. The post-heat-treatment process included four different solution annealing temperatures (954 °C, 984 °C, 1034 °C and 1154 °C), followed by two-step ageing, respectively. The microstructure evolution was revealed using scanning electron microscopy (SEM) equipped with energy-dispersive X-ray diffraction (EDS). The mechanical properties in all investigated conditions were evaluated based on tensile tests at room temperature. Using a Gaussian laser beam profile results in a fine-grained microstructure without a strong columnar orientation, while the ring beam profile produces a distinct columnar structure with larger nanodendritic grains and dislocation cells. Both beam profiles exhibit a similar proportion of Laves phase. After post-heat treatment, the Gaussian beam profile generally provides 3-7 % higher mechanical properties. The differences in mechanical properties between horizontal and vertical building directions are greater for ring-shaped laser beam profiles. Heat-treatment temperature above 1034 °C leads to recrystallisation, grain growth and the formation of carbonitrides which reduce mechanical properties. Based on the results, the proposed optimal heat-treatment temperature for both investigated laser beam shapes is 984 °C. At this temperature, tensile strength equalises between horizontal and vertical build directions while yield strength increases, which is beneficial for most applications.