A Review of Ni-based Superalloy Produced by the Additive Manufacturing Technology Powder Bed Fusion: Technologies, Materials, Applications, Challenges and Future Trends

Additive technologies are significantly changing the design and technological approach of engineers in model design. The choice of materials, the ability to apply modern industrial design (lattice structure, topology optimization, bionic design), and the ability to multi-material manufacture bring new possibilities. Similarly, the opportunities in the choice of process parameters that lead to without supports for 3D printing or improved mechanical properties are constantly evolving. This review aims to provide an overview of Powder Bed Fusion manufacturing and describe the issues in selecting optimal process parameters. The next section will focus on the specific issue of manufacturing aerospace and steam turbine parts from nickel and cobalt-based superalloys. The review discusses manufacturing issues related to macrostructure, microstructure, and crack initiation and propagation. The aim is to inspire and motivate the exchange of experience, and knowledge and the development of international collaboration among researchers addressing multidisciplinary issues. The review concludes with a summary of the research goals, vision, and future of additive technologies, which consists of the research and development of materials with unique chemical compositions and multiphysical properties.