Comparative Study on Intermediate-Temperature Deformation Mechanisms of Inconel 718 Alloys Fabricated by Additive Manufacturing and Conventional Forging

The distinct solidification behavior of additively manufactured (AM) Inconel 718 (IN718) produces a unique microstructure and precipitation response compared with its conventionally forged counterpart, leading to fundamentally different responses to heat treatment and intermediate-temperature deformation behaviors. In this work, the intermediate-temperature (450–750 °C) deformation mechanisms of laser powder bed fusion (LPBF)-fabricated and forged IN718 alloys were systematically compared under various heat-treatment conditions. Overall, under solution treatment state, the LPBF alloy exhibited fine columnar grains, a high dislocation density, and retained δ phases along the grain boundaries, whereas the forged alloy showed coarse equiaxed γ grains without the δ phase. Under solution + aging (STA) treatment, the δ phase in the LPBF alloy effectively pinned grain boundaries and enhanced flow stress, while in the forged alloy, strengthening was dominated by the uniform precipitation of γ″ and γ′ phases. Owing to Nb consumption by δ-phase formation, the STA-treated LPBF alloy contained fewer γ″/γ′ precipitates and exhibited slightly lower strength than the STA-treated forged alloy. This study demonstrates that the inherent δ phase retention and Nb segregation in LPBF-built IN718 critically influence its precipitation behavior and deformation resistance, distinguishing it from conventionally processed alloys and providing valuable insights for microstructure design in AM-built high-temperature superalloys.