Effect of hot-wire method on microstructure and mechanical properties of wire arc additive repaired superalloy

This study shows that the hot wire is an effective way to reduce the amount of undesirable Laves phase during the repair of 718Plus components, which are detrimental to the mechanical properties. The complex relationship between microstructure and hotwire was studied in detail. Five damaged components were repaired by depositing the melted 718Plus wire onto the wrought substrate using directed energy deposition-arc (DED-arc). A finite element model was used to provide clues for the thermal process analysis. The hot-wire method enhanced the cooling rate of the molten pool and suppressed the remelting behaviour of secondary dendritic arms (SDA) in the reheated zone. The resultant microstructure contained refined dendrites with more obvious SDA, which allows the production of tiny reticular Nb-rich liquid spots between dendrites during final solidification stage. These spots beyond a threshold of Nb could cause eutectic reaction, leading to the morphologic transformation from long-stripped to granular Laves phase and a lower volume fraction. Moreover, the hot-wire method hindered the dynamic precipitation of γ' phase due to the shortened precipitation time, which was responsible for the inferior mechanical properties. The heat-treatment re-optimized the precipitation of γ' phase and further dissolved Laves phase to release more Nb for γ' phase, which leads to the improvement of strength about 10 %.