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The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts

Murat Isik (Department of Automotive Engineering, Bursa Uludag Universitesi, Bursa, Turkey)
Isa Emami Tabrizi (Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul, Turkey; Composite Technologies Center of Excellence, Pendik, Turkey and Integrated Manufacturing Technologies Research and Application Center, Istanbul, Turkey)
Raja Muhammad Awais Khan (Interdisciplinary Research Center for Intelligent Manufacturing and Robotics, King Fahd University of Petroleum and Minerals, Dhahran, Saudi Arabia)
Mehmet Yildiz (Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul, Turkey; Integrated Manufacturing Technologies Research and Application Center, Istanbul, Turkey and Composite Technologies Center of Excellence, Pendik, Turkey)
Eda Aydogan (Department of Metallurgical and Materials Engineering, Middle East Technical University, Ankara, Turkey; Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul, Turkey; Composite Technologies Center of Excellence, Pendik, Turkey and Integrated Manufacturing Technologies Research and Application Center, Sabanci Universitesi, Istanbul, Turkey)
Bahattin Koc (Faculty of Engineering and Natural Sciences, Sabanci University, Istanbul, Turkey)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 7 December 2023

Issue publication date: 7 February 2024

175

Abstract

Purpose

In recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and machinery industries. Most complex or assembled parts require internal features (IF) such as holes, channels, slots, or guides for locational and mating requirements. Therefore, it is critical to understand and compare the structural and mechanical properties of additively manufactured and conventionally machined IFs.

Design/methodology/approach

In this study, mechanical and microstructural properties of Inconel 718 (Inc718) alloy internal features, manufactured either as-built with AM or machining of additively manufactured (AMed) part thereafter were investigated.

Findings

The results showed that the average ultimate tensile strength (UTS) of additively manufactured center internal feature (AM-IF) is almost analogous to the machined internal feature (M-IF). However, the yield strength of M-IF is greater than that of AM-IF due the greater surface roughness of the internal feature in AM-IF, which is deemed to surpass the effect of microstructure on the mechanical performance. The results of digital image correlation (DIC) analysis suggest that AM-IF and M-IF conditions have similar strain values under the same stress levels but the specimens with as built IF have a more locally ductile region around their IF, which is confirmed by hardness test results. But this does not change global elongation behavior. The microstructural evolution starting from as-built (AB) and heat-treated (HT) samples to specimens with IF are examined. The microstructure of HT specimens has bimodal grain structure with d phase while the AB specimens display a very fine dendritic microstructure with the presence of carbides. Although they both have close values, machined specimens have a higher frequency of finer grains based on SEM images.

Originality/value

It was shown that the concurrent creation of the IF during AM can provide a final part with a preserved ultimate tensile strength and elongation but a decreased yield strength. The variation in UTS of AM-IF increases due to the surface roughness near the internal feature as compared to smooth internal surfaces in M-IF. Hence, the outcomes of this study are believed to be valuable for the industry in terms of determining the appropriate production strategy of parts with IF using AM and postprocessing processes.

Keywords

Acknowledgements

Since acceptance of this article, the following author has updated their affiliation: Murat Isik and Bahattin Koc are at the Integrated Manufacturing Technologies Research and Application Center, Sabanci Universitesi, Istanbul, Turkey.

Citation

Isik, M., Emami Tabrizi, I., Khan, R.M.A., Yildiz, M., Aydogan, E. and Koc, B. (2024), "The effect of additively and subtractively created center internal features on microstructure and mechanical performance of inconel-718 parts", Rapid Prototyping Journal, Vol. 30 No. 2, pp. 287-304. https://doi.org/10.1108/RPJ-12-2022-0420

Publisher

:

Emerald Publishing Limited

Copyright © 2023, Emerald Publishing Limited

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