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Additively Manufactured Materials Allowables for Critical Applications / PHOEBE MAY

Swansea University Author: PHOEBE MAY

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DOI (Published version): 10.23889/SUThesis.71347

Abstract

Laser powder bed fusion, an additive manufacturing technique, brings significant opportunities for manufacturing in terms of new structural designs, higher performance, and a reduction in weight and material required. Among the various high-performance alloys adapted for laser powder bed fusion, Inc...

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Published: Swansea University 2025
Institution: Swansea University
Degree level: Doctoral
Degree name: Ph.D
Supervisor: Lancaster, R.
URI: https://cronfa.swan.ac.uk/Record/cronfa71347
first_indexed 2026-01-29T16:24:23Z
last_indexed 2026-01-30T06:53:12Z
id cronfa71347
recordtype RisThesis
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spelling 2026-01-29T16:32:27.6988386 v2 71347 2026-01-29 Additively Manufactured Materials Allowables for Critical Applications c1a2f235a189904974b4c9041e3d36fb PHOEBE MAY PHOEBE MAY true false 2026-01-29 Laser powder bed fusion, an additive manufacturing technique, brings significant opportunities for manufacturing in terms of new structural designs, higher performance, and a reduction in weight and material required. Among the various high-performance alloys adapted for laser powder bed fusion, Inconel 718, a precipitation-strengthened nickel-based superalloy renowned for its exceptional mechanical strength and thermal stability, has generated significant interest for aerospace and nuclear applications. However, for this potential to be unlocked, industry requires the creation of high calibre datasets to enable design and product certification. This requires a deep understanding and evaluation of the effect of defects, appropriate adoption of test methods, and relating the process of creating additive manufactured material to the microstructure and lifing of a component in-service. Investigation into the mechanical and microstructural performance of laser powder bed fused Inconel 718 against conventionally wrought material, with emphasis on evaluation of the influence of varying post-processing heat treatment routes on powder bed fused Inconel 718, was conducted. Variants for laser powder bed fusion included a non-heat treated variant, and two heat treated variants to improve varying mechanical properties (fatigue and creep). Microstructural analysis via advanced electron microscopy showed grain characteristics and phase variation between the additive variants and a contrast to the wrought Inconel 718. The different microstructures directly related to the mechanical properties, which were evaluated via room and elevated temperature: tensile, strain control low cycle fatigue, constant load creep testing, alongside hardness testing and small scale techniques – small punch tensile and small punch creep. Overall, the additively manufactured variants, particularly the heat treated variants, exhibited mechanical superiority compared to the wrought Inconel 718.However, the heat treatment implemented did not typically show the intended desired properties. Additionally, small scale test techniques showed general trends could be gathered but direct correlations to uniaxial tests were not accurate. Consequently, conclusions advise the need for further research into AM specific HTs and the use of small-scale testing. E-Thesis Swansea University Additive Manufacturing, Inconel 718, Laser Powder Bed Fusion, Material Science and Engineering, Mechanical Testing 10 12 2025 2025-12-10 10.23889/SUThesis.71347 COLLEGE NANME COLLEGE CODE Swansea University Lancaster, R. Doctoral Ph.D EPSRC (Industrial Case Award EP/T517987/1), American Society for Testing and Materials (ASTM) International Additive Manufacturing Center of Excellence (AM CoE) EPSRC (Industrial Case Award EP/T517987/1), American Society for Testing and Materials (ASTM) International Additive Manufacturing Center of Excellence (AM CoE) 2026-01-29T16:32:27.6988386 2026-01-29T16:05:50.5659845 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering PHOEBE MAY 1 71347__36145__5d0da0d9297c441f8ca0148ea5921b95.pdf 2025_May_P.final.71347.pdf 2026-01-29T16:23:39.4550649 Output 10295661 application/pdf E-Thesis – open access true Copyright, the author, Phoebe Eleanor May, 2025 true eng
title Additively Manufactured Materials Allowables for Critical Applications
spellingShingle Additively Manufactured Materials Allowables for Critical Applications
PHOEBE MAY
title_short Additively Manufactured Materials Allowables for Critical Applications
title_full Additively Manufactured Materials Allowables for Critical Applications
title_fullStr Additively Manufactured Materials Allowables for Critical Applications
title_full_unstemmed Additively Manufactured Materials Allowables for Critical Applications
title_sort Additively Manufactured Materials Allowables for Critical Applications
author_id_str_mv c1a2f235a189904974b4c9041e3d36fb
author_id_fullname_str_mv c1a2f235a189904974b4c9041e3d36fb_***_PHOEBE MAY
author PHOEBE MAY
author2 PHOEBE MAY
format E-Thesis
publishDate 2025
institution Swansea University
doi_str_mv 10.23889/SUThesis.71347
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 - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
active_str 0
description Laser powder bed fusion, an additive manufacturing technique, brings significant opportunities for manufacturing in terms of new structural designs, higher performance, and a reduction in weight and material required. Among the various high-performance alloys adapted for laser powder bed fusion, Inconel 718, a precipitation-strengthened nickel-based superalloy renowned for its exceptional mechanical strength and thermal stability, has generated significant interest for aerospace and nuclear applications. However, for this potential to be unlocked, industry requires the creation of high calibre datasets to enable design and product certification. This requires a deep understanding and evaluation of the effect of defects, appropriate adoption of test methods, and relating the process of creating additive manufactured material to the microstructure and lifing of a component in-service. Investigation into the mechanical and microstructural performance of laser powder bed fused Inconel 718 against conventionally wrought material, with emphasis on evaluation of the influence of varying post-processing heat treatment routes on powder bed fused Inconel 718, was conducted. Variants for laser powder bed fusion included a non-heat treated variant, and two heat treated variants to improve varying mechanical properties (fatigue and creep). Microstructural analysis via advanced electron microscopy showed grain characteristics and phase variation between the additive variants and a contrast to the wrought Inconel 718. The different microstructures directly related to the mechanical properties, which were evaluated via room and elevated temperature: tensile, strain control low cycle fatigue, constant load creep testing, alongside hardness testing and small scale techniques – small punch tensile and small punch creep. Overall, the additively manufactured variants, particularly the heat treated variants, exhibited mechanical superiority compared to the wrought Inconel 718.However, the heat treatment implemented did not typically show the intended desired properties. Additionally, small scale test techniques showed general trends could be gathered but direct correlations to uniaxial tests were not accurate. Consequently, conclusions advise the need for further research into AM specific HTs and the use of small-scale testing.
published_date 2025-12-10T05:35:15Z
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score 11.095902

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