Creep-Fatigue Behavior of Additively Manufactured Inconel 718: Mechanisms and Challenges
Abstract
This review critically examines the creep-fatigue behavior of additively manufactured (AM) Inconel 718, emphasizing distinctions from conventionally processed forms due to unique microstructures and process-induced defects. Beginning with an overview of creep-fatigue mechanisms and test methods, the paper explores how AM processes such as SLM, EBM and DED produce columnar grains, Laves and į phases, anisotropy and porosity—features that significantly affect cyclic softening, stress relaxation and crack growth.
The influence of post-processing treatments, including solution annealing, aging and HIP, is analyzed in terms of phase evolution, defect mitigation and performance under hightemperature loading. Fracture behavior is reviewed across different loading modes, build orientations and defect types, highlighting mixed-mode crack propagation and the role of grain morphology and residual stress.
A detailed evaluation of life prediction models, including strain-based, energy-based and hybrid approaches, underscores the need for AM-specific frameworks capable of capturing anisotropic and time-dependent damage. Unlike previous reviews that have primarily focused either on conventional Inconel 718 or on general fatigue and creep studies, this review consolidates creep-fatigue findings specific to AM Inconel 718, integrates insights on microstructural effects, post-processing strategies and life prediction models, and identifies critical gaps for AM-tailored design standards. Key research gaps are identified including the lack of standardized testing, limited understanding of defect criticality and inadequate postprocessing guidelines.
The review concludes with proposed directions for advancing AM Inconel 718 reliability, including the development of representative datasets, improved testing standards, microstructural mapping and scalable life prediction tools.
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