New insights on dislocation forming mechanism of nickel-based superalloy fabricated by laser powder bed fusion

In this work, the forming mechanism of dislocation in laser powder bed fusion (LPBF) built IN738LC alloy was elucidated by studying the intrinsic relationships between the density and distribution of dislocation and the orientation and size of dendrite. The substructures with different dislocation densities and cell spacings were customized by controlling solidification conditions, and analyzed by multi-scale characterizing methods. The results show that an increase in geometrically necessary dislocation (GND) density from 1.48×1014 to 1.82×1014m-2 is accompanied by a decrease in cell spacing from 1046nm to 640nm as the solidification rate increases. However, the relationship between GND density and cell spacing doesn`t follow Ashby`s model. This indicates that GNDs are not entirely generated by thermal strain itself. On the other hand, the characterization results of cell structures show that a number of misfit dislocations are formed by the thermal strain induced deflection growth of the dendrites. These prove that the dislocations are comprehensively generated by thermal strain itself and dendritic deflection growth.