Understanding the High-Temperature Deformation Behavior of Additively Manufactured Γ'-Forming Ni-Based Alloys by Microstructure Heterogeneities-Integrated Creep Modelling

Additively manufactured (AM) alloys present unique and heterogeneous microstructures due to the complex, highly dynamic laser-material interactions. These AM-inherent heterogeneities impede the widespread adoption of AM components, necessitating a profound comprehension of their impact on mechanical properties. Despite extensive research on AM of Ni-based alloys, limited attention has been paid to their creep behavior due to the time-intensive nature of creep tests and the long research cycles. Moreover, experiments and conventional alloy-centric approaches to creep modelling are deemed insufficient in quantifying the effects of AM-specific heterogeneities on creep cavity acceleration and in incorporating the microstructural evolution during creep. To address this critical knowledge gap, a novel computational framework was developed within the structure-property paradigm to unravel the intricate mechanisms governing creep properties. A mechanistic creep model was formulated based on fundamental dislocation creep mechanisms, encompassing dislocation climb-glide motion controlled by γ' precipitates, grain-boundary-sliding (GBS) resistance resulting from M23C6 carbides, and the kinetics of cavity formation. The framework integrates the in situ nucleation, precipitation, and coarsening of γ' precipitates during creep by a precipitation model. The results revealed an excellent agreement in terms of γ' precipitate evolution, creep strain, and strain-rate evolution, the predicted creep life, and times to 1% strain. By elucidating the intricate interplay between microstructural heterogeneities and creep behavior on the cavity nucleation and GBS mechanisms, the developed computational framework provided valuable insights for enhancing the performance of Ni-based alloys manufactured through AM.