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Small Scale testing of Nickel-based Superalloys produced by ALM / HANI HILAL

Swansea University Author: HANI HILAL

  • Redacted version - open access under embargo until: 10th February 2026

DOI (Published version): 10.23889/SUthesis.58781

Abstract

Nickel-based superalloys exhibit an impressive range of mechanical properties, from high temperature strength and toughness to excellent oxidation and corrosion resistance. It is for these reasons that they are heavily incorporated in a wide range of industrial sectors, particularly the aerospace in...

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Published: Swansea 2021
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Lancaster, Robert
URI: https://cronfa.swan.ac.uk/Record/cronfa58781
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first_indexed 2021-11-25T10:53:42Z
last_indexed 2021-11-26T04:16:59Z
id cronfa58781
recordtype RisThesis
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spelling 2021-11-25T11:38:51.8918690 v2 58781 2021-11-25 Small Scale testing of Nickel-based Superalloys produced by ALM 6186c954516b07fe18dfe22b4c854cca HANI HILAL HANI HILAL true false 2021-11-25 Nickel-based superalloys exhibit an impressive range of mechanical properties, from high temperature strength and toughness to excellent oxidation and corrosion resistance. It is for these reasons that they are heavily incorporated in a wide range of industrial sectors, particularly the aerospace industry where they are extensively utilised within the combustor and turbine section of a holistic gas turbine engine, where temperatures often reach arduous conditions. Although nickel-based superalloys are typically manufactured using traditional cast and wrought methodologies, the aerospace industry is becoming increasingly interested in the use of alternative manufacturing methods in an attempt to further drive gas turbine development through weight reduction and increased Turbine Entry Temperatures (TET). As such, interest regarding the use of near-net shape manufacturing technologies such as Additive Layer Manufacturing (ALM) has risen in parallel, but concerns have arisen given the metallurgical complexity of the process and the prevalence of phenomena such as anisotropic behaviour, residual stressing and structural integrity. This thesis has investigated the influence of key process parameters and variables on the mechanical and microstructural behaviour of the two-contrasting nickel-based superalloys, CM247LC and IN718. A novel miniaturised mechanical testing method, Small Punch (SP), in combination with in-depth material characterisation techniques was implemented on a series of Laser Powder Bed Fusion (LPBF) variants of differing build orientation and parameter selections. In addition to this, a robust analytical methodology was employed on a series of LPBF variants in order to ascertain process parameters’ influence on melt pool profile and both alloys relative propensity for defect formation. The findings of this work will help further the understanding of parameter selection and support a key development strategy being implemented by Rolls-Royce plc. regarding the safe incorporation of additive components into service. E-Thesis Swansea Nickel, Additive, Manufacturing 25 11 2021 2021-11-25 10.23889/SUthesis.58781 A selection of third party content is redacted or is partially redacted from this thesis due to copyright restrictions. COLLEGE NANME COLLEGE CODE Swansea University Lancaster, Robert Doctoral EngD Rolls-Royce plc, Materials & Manufacturing Academy (M2A); Grant number: EGR.751 (EGR0751-100) 2021-11-25T11:38:51.8918690 2021-11-25T10:49:05.6793813 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised HANI HILAL 1 Under embargo Under embargo 2021-11-25T11:34:30.0923741 Output 23705299 application/pdf Redacted version - open access true 2026-02-10T00:00:00.0000000 Copyright: The author, Hani Hilal, 2021. true eng
title Small Scale testing of Nickel-based Superalloys produced by ALM
spellingShingle Small Scale testing of Nickel-based Superalloys produced by ALM
HANI HILAL
title_short Small Scale testing of Nickel-based Superalloys produced by ALM
title_full Small Scale testing of Nickel-based Superalloys produced by ALM
title_fullStr Small Scale testing of Nickel-based Superalloys produced by ALM
title_full_unstemmed Small Scale testing of Nickel-based Superalloys produced by ALM
title_sort Small Scale testing of Nickel-based Superalloys produced by ALM
author_id_str_mv 6186c954516b07fe18dfe22b4c854cca
author_id_fullname_str_mv 6186c954516b07fe18dfe22b4c854cca_***_HANI HILAL
author HANI HILAL
author2 HANI HILAL
format E-Thesis
publishDate 2021
institution Swansea University
doi_str_mv 10.23889/SUthesis.58781
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
document_store_str 0
active_str 0
description Nickel-based superalloys exhibit an impressive range of mechanical properties, from high temperature strength and toughness to excellent oxidation and corrosion resistance. It is for these reasons that they are heavily incorporated in a wide range of industrial sectors, particularly the aerospace industry where they are extensively utilised within the combustor and turbine section of a holistic gas turbine engine, where temperatures often reach arduous conditions. Although nickel-based superalloys are typically manufactured using traditional cast and wrought methodologies, the aerospace industry is becoming increasingly interested in the use of alternative manufacturing methods in an attempt to further drive gas turbine development through weight reduction and increased Turbine Entry Temperatures (TET). As such, interest regarding the use of near-net shape manufacturing technologies such as Additive Layer Manufacturing (ALM) has risen in parallel, but concerns have arisen given the metallurgical complexity of the process and the prevalence of phenomena such as anisotropic behaviour, residual stressing and structural integrity. This thesis has investigated the influence of key process parameters and variables on the mechanical and microstructural behaviour of the two-contrasting nickel-based superalloys, CM247LC and IN718. A novel miniaturised mechanical testing method, Small Punch (SP), in combination with in-depth material characterisation techniques was implemented on a series of Laser Powder Bed Fusion (LPBF) variants of differing build orientation and parameter selections. In addition to this, a robust analytical methodology was employed on a series of LPBF variants in order to ascertain process parameters’ influence on melt pool profile and both alloys relative propensity for defect formation. The findings of this work will help further the understanding of parameter selection and support a key development strategy being implemented by Rolls-Royce plc. regarding the safe incorporation of additive components into service.
published_date 2021-11-25T04:15:35Z
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score 11.016235

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