William J. Jarosinski, Associate Director, Materials, Praxair Surface Technologies Inc
Currently only a small fraction of the existing NiCr Superalloys are utilized in the laser powder bed process for Additive Manufacturing (AM). These Superalloys, such as Alloy 625 and 718, are primarily used because they are considered weldable and exhibit minimal defects when printed. While great strides have been made in the AM process to obtain the microstructures and properties desired for these materials, there is significant interest in many other NiCr-alloys for critical applications in aviation and power generation. Several factors are important when fusing powder to create complex metal objects including; laser parameters, part design (large or small heat sink), process atmosphere, powder chemistry and particle size distribution. Multiple strategies are considered and assessed with regards to the reduction and elimination of cracks in difficult to weld NiCr-alloys in an effort to expand the types of Superalloys available for AM.