On the importance of nano-oxide control in laser powder bed fusion manufactured Ni-based alloys to enhance fracture properties

In this study, a series of Ni-Cr-Mo based alloys (IN625, C22 and NA282), sourced from various powder suppliers and having varying oxygen concentrations (200 ppm to 800 ppm), were printed under similar conditions using laser powder bed fusion (LPBF). Nano-oxides in the range of 20–50 nm were observed in each alloy in the as-printed state, albeit with different number densities. Room temperature tensile tests and liquid nitrogen (LN₂, -196 °C) Charpy impact tests were performed to assess the mechanical response of each alloy. The IN625 and C22 samples showed considerably lower impact energy values than the NA282, as well as lower room temperature post-necking tensile elongations, despite showing similar yield strengths and strain hardening behaviours. Fracture surface dimple sizes were shown to correlate with nano-oxide particle spacings. Nano-oxides were found in the middle of most dimples on fracture surfaces suggesting that the nano-oxides are the sites of void nucleation during fracture, despite being only 20–50 nm in size. The precursor metal powders were identified as the primary origin of the nano-oxide particles. This study highlights the critical, detrimental role that nano-oxides, typically present in LPBF metals, have on the fracture properties of these materials. In the case of the Ni-Cr-Mo alloys examined here, limiting oxide formation is critical to achieving optimal fracture properties.