Additive Layer Manufacturing (ALM) is an innovative net shape manufacturing technology that offers the ability to produce highly intricate components not possible through traditional wrought and cast procedures. Consequently, the aerospace industry is becoming ever more attentive in exploiting such technology for the fabrication of nickel-based superalloys in an attempt to drive further advancements within the holistic gas turbine. Given this, the requirement for the mechanical characterisation of such material is rising in parallel, with limitations in the availability of material processed restricting conventional mechanical testing; particularly with the abundance of process parameters to evaluate. As such, the Small Punch Creep (SPC) test method has been deemed an effective tool to rank the elevated temperature performance of alloys processed through ALM, credited to the small volumes of material utilised in each test and the ability to sample material from discrete locations. In this research, the SPC test will be used to assess the influence of a number of key process variables on the mechanical performance of Laser Powder Bed Fused (LPBF) Ni-based superalloy CM247LC. This will also include an investigation into the influence of build orientation and post-build treatment on creep performance, whilst considering the structural integrity of the different experimental builds.

Additive manufacturing (AM) is a novel near net shape manufacturing technology that joins metallic powders layer upon layer in conjunction with 3D model data and as such offers tremendous potential to a wide range of industrial sectors given its ability to produce highly intricate components with very little material wastage. Subsequently, the aerospace industry has become particularly interested in utilising AM as a means of manufacturing nickel-based superalloys for high-temperature applications, such as non-rotating components within gas turbine engines, which are traditionally fabricated through traditional cast and wrought methodologies. As a result of this, a detailed understanding of the influence of key process variables on the structural integrity of the different experimental builds is required. A semi-empirical quantitative approach for melt track analysis has been conducted and the impact on melt track sizing and defect forming mechanisms in the as-built and heat-treated condition is investigated.