Improvement in ductility of high strength polycrystalline Ni-rich Ni3Al alloy produced by EB-PVD

•High strength and high ductility of polycrystalline Ni-rich Ni3Al alloy sheets were produced.•The elongation could be enhanced from ~0.5% to ~14.6% by microstructural control.•The fracture strength (~820MPa) was enhanced by the precipitation strengthening.•This work provides a general processing for repairing the worn single crystal blades.

A 300 μm Ni-rich Ni3Al sheet was produced by electron beam physical vapor deposition (EB-PVD) and followed by different heat treatments to obtain fine γ′/γ two-phase structures with large elongation. Tensile testing was performed at room-temperature, and the corresponding mechanisms were investigated in detail. Results indicated that the as-deposited Ni3Al alloy exhibited non-equilibrium directional columnar crystal, and transited to equiaxed crystal with uniformly distributed tough γ phase after heat treatment. Meanwhile, the fracture mechanism transited from brittleness to a mixture of ductility and brittleness modes. With an appropriate heat treatment, high strength (ultimate tensile strength obtained 828 MPa) and high ductility (elongation obtained 14.6%) Ni3Al alloy has been achieved, which was due to the mesh network microstructure. A series of transmission electron microscope (TEM) characterizations confirmed that the increasing flow stress of Ni3Al alloy was attributed to the cubical secondary γ′ phase precipitates (25–50 nm) within the γ phase. This work provides a potential strategy for repairing the worn tip of single crystal engine blades using Ni-rich Ni3Al alloy by EB-PVD.