Microstructural evolution and mechanical instability of Mar-M509 superalloy fabricated by laser powder bed fusion under short-term thermal exposure

Cao, T.*; Wei, D.*; Gong, W.   ; Kawasaki, Takuro   ; Harjo, S.   ; 10 of others*

The thermal stability of microstructure and mechanical performance is crucial for the industrial application of laser powder bed fusion (LPBF) superalloy components in gas turbines and jet engines. This work investigated the microstructural evolution and strengthening mechanism of LPBF Mar-M509 cobalt-based superalloy before and after thermal exposure at 1200 C using multi-scale microstructural characterization and in situ neutron diffraction tensile testing. The as-built Mar-M509 superalloy exhibited a heterogeneous microstructural features with coarse columnar and fine equiaxed grains, both containing dendritic and cellular substructures enriched with nanoscale carbides and high-density dislocations. The ultra high strength of the as-built sample was primarily attributed to dislocation-precipitation synergistic strengthening. After thermal exposure at 1200 C for 4 h, the dendritic and cellular substructures disappeared and the dislocation density decreased significantly. This study reveals the microstructural evolution and instability of LPBF Mar-M509 superalloy under high-temperature exposure and the impacts on mechanical properties, which provides critical support for the development of cobalt-based superalloys in high-temperature application fields.