About 3D Printing Inconel Metal
Inconel alloys are widely used in the aerospace industry because of their high tensile strength, excellent fatigue and thermal fatigue resistance, and significant corrosion and oxidation resistance. However, Inconel can undergo work hardening during machining, making its parts difficult to manufacture, which makes 3D printing an ideal choice for manufacturing Inconel parts because 3D printing does not cause work hardening. In short, nickel-iron alloy has excellent properties but is difficult to conventional processing, which makes 3D printing an ideal manufacturing technology, mainly used in aerospace, Marine engineering and other fields where the demand for material corrosion resistance is extremely high.
Inconel 3D Printing at a Glance
| Application | Rocket engines, turbine blades, impellers |
| Advantages | High strength at elevated temperatures, excellent fatigue and thermal fatigue resistance, corrosion and oxidation resistant |
| Disadvantages | High cost |
| Lead Time | 3 days |
| Price | $$ |
| Minimum Feature Size | Typically 0.016” - 0.020” (0.406 mm - 0.508 mm ) |
| Layer Height | 0.0012” - 0.0016" (0.0305 mm - 0.04064 mm) |
| General Tolerances | 0.005” (0.127 mm) is possible for the first inch of height. For every inch thereafter, an additional 0.002” (0.0508 mm) is added to the tolerance. |
| Max Part Size | 10” x 10” x 10” (254 mm x 254 mm x 254 mm) |
DMLS Inconel 625
Inconel 625 Inconel printed by DMLS contains a small amount of niobium, which can harden the material without the need for age hardening. This alloy has excellent corrosion resistance and oxidation resistance, which is very suitable for Marine, energy, chemical and other strong corrosion conditions, typical applications include Marine propellers, heat exchanger housings, etc.
DMLS Inconel 625 Properties
| Tensile Strength, Yield (MPa) | Fatigue Strength (MPa) | Elongation at Break (%) | Hardness (Brinell) | Density (g/cm^3) |
|---|---|---|---|---|
| 980 ± 5 | 720 ± 5 | 33 ± 2 | 264 | 8.4 |
DMLS Inconel 718
This inconel alloy is known for its excellent high temperature properties and full strength. It maintains mechanical properties at temperatures up to 700°C and is further enhanced by precipitation hardening. In addition, the welding process of Inconel 718 is also very easy. Typical applications include gas turbine engine parts and rocket engine parts.
DMLS Inconel 718 Properties
| Tensile Strength (MPa) | Yield Strength (MPa) | Elongation at Break (%) | Hardness (Brinell) | Density (g/cm3) |
|---|---|---|---|---|
| 1060 ± 50 | 780 ± 50 | 27 ± 5 | 287 | 8.15 |
Finishes
Inconel alloy 3D printed parts can be as dense as machined parts, and can be further processed or polished. It should be noted that Inconel alloys are prone to work hardening during processing.
Standard post-treatment includes the removal of support structures during printing and the use of sandblasting to obtain a uniform surface.
When necessary, specific surface structures and features can be generated by CNC machining or polishing, but this needs to be evaluated according to the specific use requirements of the part.
In short,3D printing of Inconel alloys allows for high-density parts, which can be used for standard post-processing such as debranching and sandblasting, as well as for CNC finishing or polishing
Cost-saving Design Tips
To reduce the cost of 3D printing Inconel alloy, consider the following:
- Follow the DFM principle during design to ensure that there are enough powder discharge holes inside the model.
- Consider the support structure to prevent warping.
- Limit the amount of post-processing,Inconel alloy is easy to work hardening, and the post-processing cost is high.
- Optimize design, rational use of materials, reduce waste.
- Simplify the processing technology and only carry out the necessary post-processing.