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Hot Isostatic Pressing (HIP), Heat Treatment and Additive Manufacturing of Metal Alloys

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Metals and Alloys".

Deadline for manuscript submissions: closed (20 February 2024) | Viewed by 5147

Special Issue Editors


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Guest Editor
Department of Applied Science and Technology, Politecnico di Torino, C.so Duca degli Abruzzi 24, 10129 Turin, Italy
Interests: additive manufacturing (AM); hot isostatic pressing (HIP); Ni alloys; hot working tool steels; heat treatment; microstructure analysis
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E-Mail Website
Guest Editor
Department of Applied Science and Technology, Politecnico di Torino, C.so Duca degli Abruzzi 24, 10129 Turin, Italy
Interests: hot isostatic pressing; additive manufacturing; advanced steels; nickel-based alloys
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The hot isostatic pressing (HIP) process was developed in 1955, and since then it has undergone a radical process of renewal and development. It was first used for cladding alloys for nuclear power production purposes. Today, HIP has gained renewed interest—especially with the affirmation of the powder metallurgy near-net-shape HIP (NNSHIP) manufacturing processes and of the practice of HIP post-treating additive manufactured (AM) parts. Tailored cycles can be applied to a wide number of materials to obtain fully dense medium-to-large components starting from loose powders or to eliminate the most significant flaws inherent in AM parts. Further achievements in cycle optimization are studied to enhance the reliability and performance of components operating in highly demanding environments. The application of these techniques is highly appealing—especially for materials which are difficult to forge and to machine.

Apart from the clear technical achievements provided by HIP, new solutions in terms of HIP industrial equipment and of tooling for the NNSHIP process are currently being introduced in the market to improve the manufacturing readiness level (MRL) of such fabrication routes, and to reduce their related cost. Another topic of increasing interest is the development of reliable simulation models that help to design the tooling in NNSHIP, thus reducing the buy-to-fly index of this process.

This proposed Special Issue of Materials aims to present the latest efforts made in the abovementioned topics. Contributions are particularly invited from, but not limited to, those who are involved in:

  • Developing tailored HIP cycles for materials typically adopted for additive manufacturing, particularly (but not limited to) nickel-based superalloys, TiAl, or titanium-based alloys;
  • Understanding of microstructure evolutions due to HIP, for instance, recrystallization, second-phase dissolution or grain boundary stability and of their impact on mechanical properties;
  • Studying the effects of high pressure on phase transformations in materials or of the implementation of thermal heat treatments during or immediately after the HIP cycle;
  • Developing simulation models regarding the single or multiple steps of near-net-shape HIP processes (i.e., capsule filling and/or densification and/or microstructural evolutions during the cooling stage);
  • Assessing eventual residual defects and shape stability of components after HIP and studying potential solutions for them;
  • Studying the interactions and modifications which can be activated by elemental diffusion at the interface between the powders and the capsule used to contain them in NNSHIP.

Prof. Dr. Daniele Ugues
Dr. Emilio Bassini
Guest Editors

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Keywords

  • near-net-shape hot isostatic pressing
  • heat treatment
  • recovery of defects structure
  • additive manufacturing (AM)
  • synergy between AM and HIP
  • metallurgical transformations
  • difficult-to-forge and difficult-to-machine materials
  • demanding service performance
  • MRL
  • buy-to-fly

Published Papers (3 papers)

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Research

28 pages, 20513 KiB  
Article
Influence of Combined Heat Treatment and Hot Isostatic Pressure (HT-HIP) on Titanium Aluminide Processed by L-PBF
by Hatem A. Soliman, James Pineault and Mohamed Elbestawi
Materials 2023, 16(14), 5071; https://doi.org/10.3390/ma16145071 - 18 Jul 2023
Cited by 1 | Viewed by 1266
Abstract
Postprocessing is essential for improving titanium aluminide (TiAl) microstructure and part quality after using the laser powder bed fusion (L-PBF) method. It has been reported that Ti-48Al-2Cr-2Nb (%at) processed by L-PBF has internal defects and low fracture toughness. Microstructure control by heat treatment [...] Read more.
Postprocessing is essential for improving titanium aluminide (TiAl) microstructure and part quality after using the laser powder bed fusion (L-PBF) method. It has been reported that Ti-48Al-2Cr-2Nb (%at) processed by L-PBF has internal defects and low fracture toughness. Microstructure control by heat treatment (HT) showed a significant improvement in the ductility of the material. Alternatively, hot isostatic pressing (HIPing) could be applied to reduce the residual stresses and internal defects formed during the L-PBF. Combining the benefits of these two subsequent processes into a single predetermined process is appealing for Ti-48Al-2Cr-2Nb (%at) to minimize cost. This work presents a novel strategy to postprocess L-PBF TiAl by applying combined heat treatment and hot isostatic pressing in one process, namely HT-HIP. The process includes three cycles with different conditions (i.e., temperature, time, and pressure). These conditions were determined to achieve improved part quality and microstructure. The results show that the tensile residual stresses decreased from a peak of 249 MPa in the as-built sample to compressive stresses that peaked at −90 MPa after the HT-HIP process. The number and size of internal defects could be greatly reduced. The defects were transformed into a regular spherical shape, which is good in terms of fatigue strength. Additionally, a duplex microstructure with lamellar α2/γ colonies could be introduced for better ductility. Different levels of duplex microstructure could be achieved along with the process cycles. The grain structure using EBSD analysis showed refined equiaxed grains, which demonstrate better strength after the HT-HIP process. Twinning boundaries were also observed in the HT-HIP sample. The grain orientation tendency to the build direction significantly reduced after the HT-HIP process. The nanoindentation test was applied to evaluate the nanohardness of the as-built and HT-HIP samples. It could be demonstrated that the nanohardness is dependent on the formed phases and lamellar density inside the grains. The mean hardness value was 8.19 GPa for the as-built sample, while it was 5.48 GPa for the HT-HIP sample. Full article
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21 pages, 13770 KiB  
Article
Influence of PBF-LB Process Atmosphere on the Fatigue Strength of Hot Isostatically Post-Densified Duplex Steel Parts Produced via the Shell Core Approach
by Anke Kaletsch, Markus Sondermann, Markus Mirz, Felix Radtke and Christoph Broeckmann
Materials 2023, 16(11), 4014; https://doi.org/10.3390/ma16114014 - 27 May 2023
Cited by 3 | Viewed by 1331
Abstract
Laser-based additive manufacturing is a great manufacturing technology for producing parts of any geometry. To also increase the strength and reliability of parts produced via powder bed fusion with laser beam (PBF-LB), hot isostatic pressing (HIP) is often used to densify residual porosity [...] Read more.
Laser-based additive manufacturing is a great manufacturing technology for producing parts of any geometry. To also increase the strength and reliability of parts produced via powder bed fusion with laser beam (PBF-LB), hot isostatic pressing (HIP) is often used to densify residual porosity or lack-of-fusion defects. When components are post-densified via HIP, they do not require a high density beforehand, only a closed porosity or a dense shell. By building up samples with increased porosity, the PBF-LB process can be accelerated and productivity increased. HIP post-treatment gives the material its full density and good mechanical properties. However, with this approach, the influence of the process gases becomes important. Either argon or nitrogen is used in the PBF-LB process. It is assumed that these process gases are trapped in the pores and thus have an influence on the HIP process and also the mechanical properties after HIP. In this study, the influence of argon and nitrogen as process gases on the properties of duplex AISI 318LN steel after powder bed fusion with laser beam and hot isostatic pressing is investigated for the case of very high initial porosities. Full article
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19 pages, 17611 KiB  
Article
Investigation of the Properties of 316L Stainless Steel after AM and Heat Treatment
by Patrik Petroušek, Tibor Kvačkaj, Jana Bidulská, Róbert Bidulský, Marco Actis Grande, Diego Manfredi, Klaus-Peter Weiss, Róbert Kočiško, Miloslav Lupták and Imrich Pokorný
Materials 2023, 16(11), 3935; https://doi.org/10.3390/ma16113935 - 24 May 2023
Cited by 7 | Viewed by 2027
Abstract
Additive manufacturing, including laser powder bed fusion, offers possibilities for the production of materials with properties comparable to conventional technologies. The main aim of this paper is to describe the specific microstructure of 316L stainless steel prepared using additive manufacturing. The as-built state [...] Read more.
Additive manufacturing, including laser powder bed fusion, offers possibilities for the production of materials with properties comparable to conventional technologies. The main aim of this paper is to describe the specific microstructure of 316L stainless steel prepared using additive manufacturing. The as-built state and the material after heat treatment (solution annealing at 1050 °C and 60 min soaking time, followed by artificial aging at 700 °C and 3000 min soaking time) were analyzed. A static tensile test at ambient temperature, 77 K, and 8 K was performed to evaluate the mechanical properties. The characteristics of the specific microstructure were examined using optical microscopy, scanning electron microscopy, and transmission electron microscopy. The stainless steel 316L prepared using laser powder bed fusion consisted of a hierarchical austenitic microstructure, with a grain size of 25 µm as-built up to 35 µm after heat treatment. The grains predominantly contained fine 300–700 nm subgrains with a cellular structure. It was concluded that after the selected heat treatment there was a significant reduction in dislocations. An increase in precipitates was observed after heat treatment, from the original amount of approximately 20 nm to 150 nm. Full article
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