Additively Manufacturing of Single-Crystal Superalloys: Linking Processing-Microstructures-Mechanical Properties

Single-crystal (SX) superalloys are indispensable for high-temperature components in advanced aeroengines, valued for their exceptional creep resistance, fatigue life, and thermal stability. Traditional manufacturing methods such as directional solidification and investment casting limit achievable shapes, efficiency, and repair flexibility. Additive manufacturing (AM) technologies—including laser-directed energy deposition and powder bed fusion—have recently enabled new possibilities for fabricating and repairing SX superalloy parts. However, the inherent challenges of AM, such as steep thermal gradients, rapid solidification, and cyclic stresses, complicate the maintenance of crystallographic integrity, suppression of stray grains, and control of microstructural uniformity. Fundamental quantitative understanding of how processing influences microstructure and mechanical properties in AMed SX superalloys is still lacking.This Research Topic aims to advance knowledge of the processing-microstructure-property relationships in additively manufactured SX superalloys. By leveraging process engineering, in situ characterization, multi-scale modeling, and mechanical evaluation, we seek to unveil the mechanisms governing crystal growth, defect formation, and microstructural evolution, and to establish clear connections between manufacturing parameters, thermal history, microstructure, and mechanical performance (including creep, fatigue, and fracture).The scope of this Research Topic is defined by its focus on the fabrication, repair, and optimization of SX superalloys by additive manufacturing. To gather further insights, we welcome articles covering, but not limited to, the following themes:• Crystallographic orientation control and stray grain suppression• Rapid solidification dynamics and microstructure evolution• Thermo-mechanical coupling and its effects on properties• Mechanical properties and deformation mechanism of AM metals• Multi-scale processing-structure-property modeling supported by experiments• Data-driven and machine learning-assisted process optimization Topic editors: Zixu Guo, Erlei Li, Pengfei Wu, Yang Li Source: https://www.frontiersin.org/research-topics/77201/additively-manufacturing-of-single-crystal-superalloys-linking-processing-microstructures-mechanical-properties