Journal of Alloys and Compounds 904 (2022) 164099

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Journal of Alloys and Compounds

journal homepage: www.elsevier.com/locate/jalcom

Investigation of laser scan strategy on tensile and microstructural

characteristics of inconel 718 fabricated by DMLS process ]]
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⁎
K. Bintu Sumanth , V. Srinivasan
Annamalai University, Chidambaram, Tamil Nadu, India

a r t i cl e i nfo a bstr ac t

Article history: Metal additive manufacturing, mainly direct metal laser sintering (DMLS), is presiding over all the me­
Received 15 December 2021 chanical and manufacturing segments with its fascinating progress. Several studies have proved that the
Received in revised form 29 January 2022 build orientation of the additive manufacturing (AM) process is very significant and influential on the
Accepted 2 February 2022
mechanical properties. In this study, In718 samples were fabricated through DMLS with different Scan
Available online 3 February 2022
Orientation Strategies (SOS) of 670 (sample A), 670 + 900 (sample B), and 900 (sample C), and their impacts
on mechanical characteristics and microstructures were discussed. The study revealed that due to a higher
Keywords:
DMLS rate of elemental segregation, sample B exhibited a UTS of 1231 Mpa, which is approximately 17.21% greater
Inconel 718 than sample C and 8.36% greater than sample A. In the same way, the percentage elongation of sample C is
SOS 21% greater than that of sample B and 10.5% superior to sample A. Images obtained using a scanning
Tensile electron microscope (SEM) and an optical microscope (OM) were analysed to support the specimens'
Laser-PBT fractographies, columnar pattern growth, and elemental segregation. The fractured surfaces of tensile
samples A & C revealed uniform fracture and equiaxed failures with deep dimples, whereas the fractured
surface of sample B revealed the presence of an intermetallic configuration displaying brittle and low plastic
deformation.
© 2022 Elsevier B.V. All rights reserved.

1. Introduction contender for the production of rocket engine combustion chamber

In metal based additive manufacturing, there are lot of integral
technologies having flexibility of high ordered intricacy, melting
conditions and parametric inputs like laser power, standoff dis­
tances, part print coordinating axis [1]. Metal additive manu­
facturing processes have interesting flexibility in the operation of
intricate shapes and structures. Powder bed technology (PBT) is a
process that develops precise limits and attracts features to produce
metal manufacturing parts [2,3]. Direct metal laser sintering (DMLS),
considered an extension of the SLM process, is able to process re­
active materials like Inconel 718 and provides higher sintered
magnitudes and energy distribution by varying laser power and scan
velocity. Remarkably, DMLSed Laser-PBT is getting a passionate in­
terest in producing parts for the aerospace, automotive, and bio­
medical industries. DMLSed Laser-PBT has emerged as a leading
⁎
Correspondence to: Department of Manufacturing Engineering, Annamalai
University.
E-mail addresses: bin2jos@gmail.com (K. Bintu Sumanth),
srinivraghavan@yahoo.com (V. Srinivasan).
(Launcher space E1 engine) [4–6].
The crystal structure of IN718 is usually precipitation hardened
γ’-Ni3 (Al, Ti) and γ"-Ni3Nb [7]. The standard process for manu­
facturing modules with IN718 employs wrought and cast methods.
IN718 has good creep-rupture strength at a temperature of about
700 °C (1290°F). These nickel-based super alloys are used ex­
tensively in aerospace engine chambers, automotive jet engines,
manifolds, and critical supporting structures [8]. The build orienta­
tion adopted in additive manufacturing is one of the vital factors that
influence the mechanical properties of the components. The occur­
rence of manufacturing defects is very common and significantly
affects the mechanical properties. For example, the occurrence of
small pores is very detrimental to the mechanical performance of
the components. However, there are a bunch of post-processing
techniques available to rectify these defects. [9].
Specimen build orientation (X-Y) and build platform temperature
are the important factors to study while investigating the mechan­
ical properties of metal-additive manufactured materials.
Regrettably, necessary data pertaining to the above-mentioned fac­
tors is scanty. The BDO (build direction orientation) has a significant
influence on tensile, fracture, and microstructural behavior, and all
results are associated with it. According to earlier research [10–12],

https://doi.org/10.1016/j.jallcom.2022.164099
0925-8388/© 2022 Elsevier B.V. All rights reserved.
K. Bintu Sumanth and V. Srinivasan
Fig. 1. a) Processing Parameters of Laser-PBT (DMLS) & 1.b) Orientation patterns of Laser Scan.
the strength of the IN718 components, manufactured using Laser-
PBT, is inadequate for direct metal-based industrial applications.
Hence, in this study, IN718 samples were fabricated using the DMLS
process and tested for tensile and microstructural characterization.
For detailed discussion in this investigation, the influence of dif­
ferent SOS on the tensile and microstructural characterization have
taken up. A fractograph analysis was also performed on the tensile
specimens using a Scanning Electron Microscope (SEM) to validate
the tensile tests.
2. Materials and methods
Inconel 718 super alloy powder of size 40μ approximately was
procured from "VEERO METALS,” Bangalore, where the chemical
composition of the powder is in compliance with EOS nickel alloy
standards of UNSN07718 and AMS 5662. VEEROMETALS, Bangalore
has facilitated the DMLS EOS M290 machine used for Additive
Manufacturing of IN718 with a design specification of F3055–14a
listed by ASTM for AM nickel alloy sintered using Laser-PBT.
A powder bed made of IN718 was focused on a high power laser
beam of 400 W melted locally at a specified location, and finally
solidified. As a result, the addition of material at each layer built the
physical 3D geometries adhering to the AM shaping principle in
accordance with ASTM52900–2015 [3]. Based on the literature,
substantial process parameters like hatch distance, laser power, scan
velocity, and specimen layer thickness were selected and implied for
this investigation. Fig. 1(a) shows the different processing para­
meters used in this study and Fig. 1(b) shows the orientation pat­
terns of alternative layers of IN718. The three scan orientation
strategies used in this investigation are sample A with a 670 or­
ientation, sample B with a 670 + 900 orientation, and sample C, or­
ientated with a 900 pattern. Table 1 presents the different process
parameters used in this investigation to study the tensile char­
acteristics of IN718 samples. An optical microscope, facilitated by
MICROLABS Chennai, was employed to evaluate the microstructural
characterization and layer orientation of DMLSed samples. In total,
nine tensile samples were prepared according to ASTM E8 and tested
on the FIE BLUESTAR UTS machine. A Scanning electron microscope
(SEM) by JEOL was employed to evaluate the fractography of the
tensile specimens used in this study.
Table 1
Process Parameters of DMLSed IN718 AM.
Test Test Degree of Laser Scan
Samples Orientation Power Velocity
P (W) Vs (mm/S)
TENSILE Sample A 67 300 1500
Sample B 67 + 90
Sample C 90
Journal of Alloys and Compounds 904 (2022) 164099
3. Results and discussions
3.1. Microstructural analysis
The surface of the DMLSed samples was neatly ground, polished,
and etched by adopting standard operating procedures specified by
ASTM. The etching agent, kalling 2, was used to surface the micro­
structure of the specimens. Fig. 2(a) shows the optical micrographs
that expose the build direction of the DMLSed IN718 alloy. Moreover,
the layered structure of melt pool track is clearly spotted on the mi­
crographs, and those tracks are termed "fish scale" structure. [13–15].
The scanning direction of all the samples printed was in a hor­
izontal direction. Fig. 2(b) shows the layered structure of the spe­
cimens, and it is evident that the layered structure of samples A, B,
and C has 67, 670 + 900 and 900 orientations, respectively; the white
arrow mark represents the 900-laser scan track, whereas the 670
laser scan track was represented by an orange arrow mark. It can be
seen from Fig. 3(a) that the microstructure of the DMLSed specimen
is directly influenced by the geometry of the melt pool obtained
during the DMLS printing process.
The fish scale pattern is obtained on the top surface of the sample.
Beneath these fish- scale layers the dendrites of the next layer grew
and stretched towards the printing direction. Due to high element
segregation, the epitaxial growth of columnar grains formed an in­
terdendritic structure by meshing with subsequent layers. [16–21].
Dendritic solidification is the most familiar solidification type;
however, cellular solidification is also possible. The type of solidifi­
cation depends on the liquid to solid, thermal, physical boundary
conditions and interface velocity of the melt pool. During the soli­
dification of deposited material, IN718 have a tendency to show
dendritic behavior. As formation of solid, Nb, Ti, Mo, and other ele­
ments tend to segregate to interdendritic regions [22]. If Nb segre­
gates while in solidification, it generate interdendritic regions rich in
Nb. If not suitably homogenized, these regions can form Laves phase,
which is detrimental to mechanical properties. Antonsson et.al [23]
have observed that during rapid solidification, less amount of Nb is
obtained in the interdendritic regions with minimal Laves phase.
Thus it is confirmed that lower rate of- laves phase formation on the
specimens proved that the formation of Nb is minimum. Fig. 3(b)
symbolises overlapping of melt pool on the grain growth direction of
sample B. Increase in solidification rate changes the dendritic pat­
tern into cellular pattern and become diffusion less lately. Fig. 3(c) &
(d) clearly shows that the samples A & C were having homogeneous
growth and did not found any meshing nature, which is ascribed to
Hatch the single orientation pattern of the samples.
Space
H (Μm)
3.2. Mechanical Properties
0.1
Fig. 4. (a) & (b) shows the graphical representation of mechanical
properties such as ultimate tensile strength, yield strength, and
2
K. Bintu Sumanth and V. Srinivasan Journal of Alloys and Compounds 904 (2022) 164099

Fig. 2. Microstructure of DMLSed IN718 a) fish scale structure b) based on scan direction 67 & 90-degree orientation track path.

Fig. 3. Microstructure of Laser-PBT IN718 super alloy a) showing meshing nature of sample B, b) melt pool overlapping representation, c) Homogeneous grain growth towards
next printing layer of sample A& C.

Fig. 4. (a & b) Graphical plot of tensile strength to comparing DMLSed IN718 samples.

elongation at rupture for all the IN718 samples used in this study. It UTS of sample C. The yield strength of sample B is found to be
is clearly evident that Sample B exhibits better UTS and YS in 1001 MPa which 9.27% greater than YS of sample A and 20.16%
comparison with samples B and C. The UTS of sample B is 1231Mpa, greater than YS of sample C. The percentage elongation of sample B
which is 17.21% greater than UTS of sample A and 8.36% greater than is 21% lesser than sample A and 10.5% lesser than sample C. The

3
K. Bintu Sumanth and V. Srinivasan Journal of Alloys and Compounds 904 (2022) 164099

Table 2
Tensile Characteristics of IN718 produced through different AM techniques.

MACHINE TYPE AM Technique YEILD STRENGTH ULTIMATE TENSILE STRENGTH ELONGATION (%) REF
(MPa) (MPa)
EOS M280 NA 920 1084 21.9 [8]
1020 1180 22 [25]
YLR 5000 DLD 1007 1221 16 [20]
Tensile stress results of DMLSed IN718 AM
(current study)
S.no Test Sample Degree of Orientation UTS Yield strength Elongation
(MPa) (MPa) (%)
1 Sample A 67 1190 ± 14 916 ± 14 19 ± 0.28
2 Sample B 67 + 90 1231 ± 15 1001 ± 15 16 ± 0.24
3 Sample C 90 1163 ± 12 833 ± 12 21 ± 0.32

prescribed table values are mean strength values by the average of
three test results.
This may be ascribed to the resultant microstructure caused by the
high cooling rates involved in the laser sintering process. On the other
hand, the value of elongation of sample B at rupture shows a lower
ductility in comparison with samples A and C, which is attributed to
the slight embrittlement of samples due to the formation of inter­
dendritic regions with minimal Laves phase. The above statement is
well correlated with the findings of D.G. Krishna et al., where the in­
terdendritic meshing nature of columnar grains grew in the direction
of printing leads and increased the brittle nature of samples. [24].
Table 2 shows the comparative mechanical behaviour of IN718
manufactured through various AM techniques. It is clearly observed
that the IN718 samples obtained in this investigation have competed
appreciably with the samples obtained through other techniques.
From the studies of J.R. Zhao et al., it was observed that the UTS of
additively manufactured IN718 was found to be 1180 MPa and its
yield strength is 1020 MPa [25]. However, in this study, we were able
to achieve 1231 Mpa of UTS, which is approximately 7% greater than
the UTS of the above referred study. On the other hand, the increase
in UTS was compensated by the loss of yield strength, which was
mainly attributed to the scan strategy of 67 + 90° orientation.
Fig. 5 shows the micrograph images produced by using the image
analysis software ImageJ. The images clearly show that the percentage
of pores is significantly lower in the case of Sample B shown in Fig. 5(a)
when compared to those with samples A and C shown in Figs. 5b and
5(c), implying that the effect of pores on tensile properties is minor.
The above results are well correlated with the studies of
Santhosh K. et al. where if the percentage porosity is less than one,
the pores have little effect on the tensile strength or elongation to
failure when these defects are caused by higher energy diffusion
[26]. Sample B has relatively lower elongation when compared to
samples A and C, which is attributed to columnar grain boundary
orientation in the direction of tensile, stress that finally leads to easy
grain boundary delamination. The tensile fracture surfaces of sample
B, which exhibited trans-granular failure associated with fine, en­
trenched, and intermetallic-like Ni3Nb platelet particles surrounded
by uniform equiaxed dimples, are depicted in Fig. 6(a) and 6(b).
Also, the presence of secondary particles like metal component
carbides (MC) was observed on the fracture surface of the IN718

Fig. 5. pores cleavage of sample B and A&C using ImageJ analysis software.

4
K. Bintu Sumanth and V. Srinivasan
Fig. 6. a & b. Tensile fracture surface behaviour of sample B cracks formed in brittle intermetallic configuration with movement along grain boundaries, c & d showing evidence of
uniform dimples and crack initiations, and e and f showing cleavage facets, micro voids, and micro cracks by mono-oriented build direction along grain boundaries.
samples, showing brittle and low plastic deformation. It is evident that
the cracks that form in the Nb and Ti-rich MC carbides of DMLSed
IN718 act as crack initiators and subsequently propagate along the
interdendritic regions that lead to the fracture of the materials.
Fig. 6(c) & 6(d) clearly shows the fractured surface of samples A
(670) and C (900) having uniform dimple surfaces, ductile in nature,
and built on single orientation printing. Intergranular cracking through
grain boundaries was predominant on the fractured surfaces of sam­
ples A and C. In this single-oriented print, grains were delaminated
when the samples were subjected to tension. The fracture surface
characteristics of the DMLSed Samples A & C showed dendritic pat­
terns with superior cracking nature along the interdendritic regions,
showing uniform fracture and equiaxed failures with deep dimples.
The fractured surface of IN718 samples A (670) and C (900) is
clearly visible in Fig. 6(e) and 6(f). Large cleavage facets with irre­
gular dimple locations were observed, and these cleavage facets
appeared to be the result of tensile fracture occurring by cutting
through the aligned platelets. The plastic instability in between the
facets was supposed to induce dimpled rupture. The fractured sur­
faces of IN718 specimens, exhibited a cup-and-cone type of ductile
fracture with fine dimples covering the fracture surface [27].
4. Conclusion
IN718 samples for microstructural analysis and tensile char­
acterization were fabricated using the DMLS process by adopting
5
Journal of Alloys and Compounds 904 (2022) 164099
Laser PBT. Three different kinds of samples with three different Scan
orientation strategies (670, 670 +900, and 900) were taken up for this
investigation, and the following conclusions were drawn.
• The microstructure of the DMLSed specimen was directly influ­
enced by the geometry of the melt pool obtained during the
DMLS printing process, and a fish scale pattern was obtained on
the top surface of the sample, beneath these fish scale layers, the
dendrites of the next layer grew and stretched towards the
printing direction for sample B.
• The columnar grains of samples A & C were in regular orientation
where the grain growth is progressive towards the printed di­
rection, which is mainly single-orientation building. OM analysis
of sample B revealed, that the samples were built in meshing
nature with higher elemental (Nb –Mo) segregation in inter­
dendritic region, as well as precipitation, which is made-up to
Laves phase that is detrimental to tensile properties.
• In tensile studies, sample B exhibited UTS of 1231 Mpa, which is
approximately 17.21% greater than sample C and 8.36% greater
than sample A, due to the higher rate of elemental segregation. In
the same way, the percentage elongation of sample C is 21%
greater than that of sample B and 10.5% superior to sample A.
• Fractured surfaces of tensile Samples A & C revealed the dendritic
patterns with significant cracking along the interdendritic re­
gions showing uniform fracture and equiaxed failures with deep
dimples. Fractured surface of sample B revealed the presence of
K. Bintu Sumanth and V. Srinivasan
secondary particles, such as MC carbides and intermetallic con­
figuration showing brittle and low plastic deformation.
CRediT authorship contribution statement
K. Bintu Sumanth: Conceptualization, Methodology, Software,
Investigation, Writing – original draft. V. Srinivasan:
Conceptualization, Validation, Resources, Writing – review & editing,
Supervision, Project administration.
Declaration of Competing Interest
The authors declare that they have no known competing fi­
nancial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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