Fig. 1 Morphology characterization of novel Ni-based superalloy powder particles: a microstructure morphology of powder particle, b distribution of powder particle size, c element distribution of powder particle

Fig. 2 Schematic diagram of laser power, scanning speed, and scanning strategy: a parameter optimization and the cube specimens of size 10 mm × 10 mm × 15 mm obtained from SLM experiment, b scanning strategy of SLM

Fig. 3 Metallographic structure of the novel superalloy fabricated at various scanning speeds and laser powers

Fig. 4 Evolution of relative density with different laser parameters: a relationship between power, scanning rate, and relative density, b relationship between energy density and relative density

Fig. 5 Metallographic structure and SEM images of the XZ plane of as-printed samples at different energy densities: a, b 37.9 J/mm3, c, d 51.1 J/mm3, e, f 71.0 J/mm3, and g, h 104.2 J/mm3

Fig. 6 Measured melt pool depth, melt pool width, and depth-to-width ratio of melt pool for SLM produced under different energy densities

Fig. 7 Inverse pole figures (IPFs), band contrast (BC), average grain size distribution, and pole figures (PF) at different energy densities: a, e, i, m 37.9 J/mm3, b, f, j, n 51.1 J/mm3, c, g, k, o 71.0 J/mm3, d, h, l, p 104.2 J/mm3

Fig. 8 TEM observations from the XY plane in the SLM samples with η = 71.0 J/mm3: a, b the bright field TEM micrograph in the XY plane, c the selected area electron diffraction (SAED) pattern, d high-angle annular dark-field scanning transmission electron microscopy image and the relevant EDS mapping

Fig. 9 Tensile performance of printed alloys at varying energy densities: a engineering stress-strain curves, b comparison of tensile properties [44,45,46,47,48,49,50,51,52,53,54,55,56,57,58]

Fig. 10 Tensile performance of printed alloys with an energy density of 51.1 J/mm3 at 750 °C: a engineering stress-strain curves, b nanoscale γ′ phase particles, c comparison of tensile properties [48,49,50,56,59,60]

Fig. 11 SEM fracture images of printed alloys at varying energy densities: a, e, i 37.9 J/mm3, b, f, j 51.1 J/mm3, c, g, k 71.0 J/mm3, d, h, l 104.2 J/mm3

Fig. 12 Fracture morphologies of the printed alloy at a laser energy density of 51.1 J/mm3 under tensile testing at 750 °C

Fig. 13 SCI of various alloys based upon solidification curves calculated using Pandat with PanNi2022a database