A Novel γ′-Strengthened Nickel-Based Superalloy for Laser Powder Bed Fusion

An experimental printable γ′-strengthened nickel-based superalloy, MAD542, is proposed. By process optimization, a crack-free component with less than 0.06% defect was achieved by laser powder bed fusion (LPBF). After post-processing by solution heat treatment, a recrystallized structure was revealed, which was also associated with the formation of annealing twins. After the aging treatment, 60–65% γ′ precipitates were obtained with a cuboidal morphology. The success of printing and post-processing the new MAD542 superalloy may give new insights into alloy design approaches for additive manufacturing.