Investigating the Influence of Al Contents on Microstructure and Mechanical Properties of Ni3Al Superalloy Fabricated by Twin Wire‐Based Direct Arc Energy Deposition

In situ synthesis of Ni 3 Al by simultaneously feeding both Ni and Al wires into the molten pool is a common wire‐based additive manufacturing technology for Ni 3 Al superalloys. However, Ni 3 Al superalloys within a composition gap still have not yet been synthesized. The optimal composition range has also not been investigated yet. Herein, Ni 3 Al superalloys with Al equivalents between 17 and 25 at.% are fabricated by twin wire‐based direct arc energy deposition by adjusting the relative feeding speed. Microstructural analysis shows that the solidification products generate no γ′ precipitation when Al content is 17 at.%. Al promotes the formation of γ′ phase, as the Al content increases, the deposited Ni 3 Al superalloys with 20–25 at.% Al consist of dendritic γ + γ′ dual phase and interdendritic γ′ single phase. The proportion of γ + γ′ dual phase gradually increases with decreasing Al contents, whereas the tensile strength and elongation gradually increase. The Ni 3 Al superalloys (20 at.% Al) with the most γ + γ′ dual phase exhibit the highest tensile strength and elongation (939 MPa and 25.7%, respectively). Fracture analysis shows that the dislocation decomposition and stacking fault shearing mechanisms allow dislocations to continuously cut through γ′ precipitations to maintain deformation, which is responsible for high tensile strength and ductility.