Pre-softening HIP treatment enabled crack-healing and superior mechanical properties for René 142 superalloy fabricated via laser powder bed fusion

The generation of defects, such as cracks and pores, presents significant challenges for high-strength metals and alloys fabricated by the quick-emerging additive manufacturing technology, and subsequent post-processing treatments are often necessary before their practical applications. In this work, a novel heat treatment approach, involving a pre-softening treatment before hot isostatic pressing (HIP), is developed to facilitate the crack-healing in René 142 superalloy produced through laser powder bed fusion. Results demonstrate that René 142 alloy exhibits a propensity for severe cracking across a wide range of printing parameters, primarily in the form of solidification cracks and liquation cracks. These cracks are formed mainly due to a wide solidification range, the presence of a liquid film, and the concentration of residual stress. The pre-softening solution heat treatment significantly reduces dislocation density and residual stress levels, and the subsequent HIP together leads to a defect-free, dense structure for René 142 superalloy. Consequently, the René 142 alloy processed by the pre-softening HIP treatment achieves an excellent combination of yield strength (850 MPa), ultimate tensile strength (1227 MPa), and elongation (13.7 %), with pseudo-equiaxed grains (120–150 μm) and square γ′ precipitates (approximately 540 nm). These findings provide valuable insights for exploring crack elimination methods in other nickel-based superalloys fabricated through additive manufacturing.