Additive Manufacturing of Nickel‑Based Superalloys

Ni-based alloys, commonly known as superalloys, offer excellent mechanical strength and oxidation/corrosion resistance at elevated temperatures, making them ideal for aerospace and power generation applications, mainly where the high strength at elevated temperatures is required. Casting and extensive post-machining, which are traditionally used for the production of Ni-based alloys, pose challenges such as poor machinability and high material waste. Thus, additive manufacturing (AM) has emerged as a promising alternative for fabricating complex Ni-based components more efficiently and with reduced material loss. However, AM still faces several challenges, including defect formation, anisotropic mechanical behavior, and microstructural mismatches. This chapter reviews the various AM techniques applied to Ni-based superalloys, emphasizing the roles of alloying elements, the key challenges associated with AM processing, and the effective strategies developed to mitigate these issues. Additionally, this chapter discusses the formation and evolution of phases in additively manufactured Ni-based alloys and the corresponding strengthening mechanisms that govern their high-temperature performance.