Additive Manufacturing of High-Gamma Prime Nickel-Based Superalloys through Selective Laser Melting (SLM)

High-ℽ' nickel-based superalloys are abundantly used in the aerospace, marine, nuclear, and chemical industries where excellent corrosion and oxidation resistance, superior mechanical properties, and exceptional high-temperature performance are required. However, selective laser melting (SLM)-based additive manufacturing (AM) of high-ℽ' nickel-based superalloys pose significant challenges due to these alloys’ complex chemistry. With multiple alloying elements and high aluminum + titanium fraction, these materials when consolidated through SLM form various secondary phases severely affecting the processability leading to the formation of cracks. The objective of this review is to summarize the progress made so far on SLM of high-ℽ' nickel-based superalloys with a special emphasis towards elucidating the relationships between processing, microstructures, and properties in this alloy system.