Issues $\rightarrow$ Volume 26, Issue 4 (2025)

Heat-Resistant Powder Alloys in Additive Manufacturing: Materials, Application, and Perspectives

DURIAGINA Z.A.$^{1}$, LEMISHKA I.A.$^{1}$, ROMANOVA T.Ye.$^{2,3}$, TROSTIANCHYN A.M.$^{1}$, KULYK V.V.$^{1}$, EFANOV V.S.$^{4}$, PRIAKHIN V.Ye.$^{1}$, and PAVLYSH V.A.$^{1}$

$^1$Lviv Polytechnic National University, 12 Bandera Str., UA-79000 Lviv, Ukraine
$^2$Anatolii Pidhornyi Institute of Mechanical Engineering Problems of the N.A.S. of Ukraine, 2/10 Komunalnykiv Str., UA-61046 Kharkiv, Ukraine
$^3$Leeds University Business School, University of Leeds, LS2 9JT Leeds, United Kingdom
$^4$National University ‘Zaporizhzhia Polytechnic’, 64 Zhukovskoho Str., UA-69063 Zaporizhzhia, Ukraine

Received / Final version: 07.10.2025 / 17.11.2025 Download PDF logo PDF

Abstract
Stainless steels and heat-resistant alloys of the Fe–Cr, Fe–Mn, Fe–Mn–N, Fe–Ni, and Fe–Cr–Ni systems are leading materials for critical components, particularly, in the aviation and energy sectors. Their use in the form of powder alloys expands the possibilities of additive technologies and enhances the functional properties of products made of them. Well known that, simultaneously, technological problems must be solved and computer-modelling methods implemented to optimise the microstructure design of future products. The article systematises current understanding of the features of phase-state formation during laser-powder bed fusion (LPBF) and direct energy deposition (DED) processes, the influence of 3D-printing parameters on the morphology of γ- and γ′-phases, as well as on the formation of secondary phases such as topologically close-packed (TCP) ones and carbides. The main mechanisms of defect formation, residual stresses and porosity, which determine the operational properties of products, are considered. Effective approaches to enhancing structural stability are presented, including the use of thermomechanical post-treatment hot isostatic pressing (HIP), optimisation of granulometric and chemical compositions, application of computer modelling methods (CALPHAD, machine learning (ML), neural networks, etc.) and the implementation of in-situ alloying technologies. Special attention is given to the latest trends in the development of additive technologies for nickel superalloys, particularly, the creation of next-generation additive-manufacturing (AM) oriented materials, digital process monitoring, and the transition to a sustainable (‘green’) manufacturing concept. The review conducted allows for the identification of key scientific and technological directions to ensure the stability of the microstructure, crack resistance, and durability of nickel-superalloy components produced by additive-manufacturing methods.

Keywords: additive manufacturing, nickel superalloys, microstructure stability, strengthening phases, porosity, in-situ alloying.

DOI: https://doi.org/10.15407/ufm.26.04.***

Citation: Z.A. Duriagina, I.A. Lemishka, T.E. Romanova, A.M. Trostianchyn, I.S. Litvinchev, V.V. Kulyk, V.S. Efanov, V.E. Priakhin, and V.A. Pavlysh, Heat-Resistant Powder Alloys in Additive Manufacturing: Materials, Application, and Perspectives, Progress in Physics of Metals, 26, No. 4: ***–*** (2025)

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