Effects of thermal history of in-situ thermal management on as-built property heterogeneity of plasma arc additively manufactured Inconel 625

In-situ thermal management (ISTM) is one of the most prospective approaches to alleviating heat accumulation and achieving progressive forming for arc-based additive manufacturing. The aim of this study was to investigate the influences of thermal history, i.e., the cooling rate and the intrinsic heat treatment (IHT), of ISTM on as-built property heterogeneity of plasma arc additively manufactured Inconel 625 thin-wall deposit. The thermal history is obtained from numerical simulation. Results show that the variation of the thermal history of ISTM results in the bottom-up varied cooling rate and IHT, which together lead to the location-heterogeneous primary dendrite arm spacing, interdendritic phases and grain size. IHT of each layer is quantified by temperature-time integration (TTI), and Gaussian distributed TTI (above 600 °C) indicates the middle region of the deposit with ISTM is subjected to the most intense IHT. Compared with the counterpart of the conventional interlayer cooling strategy, the intensified high-temperature IHT of ISTM contributes to significant mitigation of micro-segregation, i.e., the brittle-hard interdendritic phases reduce 61.9%. Furthermore, a weighted value of cooling rate and TTI is innovatively introduced to depict the heterogeneity of mechanical property, which presents an exponential growth of ultimate tensile strength with the weighted value. Moreover, the layer-by-layer decreased heat input and the high-temperature preheating between layers of ISTM contribute to a certain residual stress release effect along the building direction.