Waspaloy®

metal

nickel superalloy — γ'-precipitation-hardened

UNS N07001Alloy 685AMS 5544AMS 5704PWA 683Ni-Cr-Co superalloy

Density

8.19 g/cm³

YS (LPBF stress-relieved (1050°C / 1h / AC) (XY))

700–870 MPa

UTS (LPBF stress-relieved (1050°C / 1h / AC) (XY))

960–1150 MPa

Elongation (LPBF stress-relieved (1050°C / 1h / AC) (XY))

12.0–28.0 %

Thermal conductivity

11.7 W/m·K

Composition — UNS N07001 / ASTM B637 / AMS 5544

Element	Min %	Max %	Notes
Ni	bal.		balance
Cr	18.00	21.000	Oxidation resistance and solid-solution strengthening; forms Cr₂O₃ scale
Co	12.00	15.000	Solid-solution strengthening; raises γ' solvus temperature for better high-T stability
Mo	3.50	5.000	Solid-solution strengthening; corrosion resistance in reducing environments
Al	1.20	1.600	γ' (Ni₃Al,Ti) former — primary precipitate strengthener

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Mechanical & thermal properties — 3 conditions

Property	LPBF stress-relieved (1050°C / 1h / AC) (XY)	LPBF SA + double-age (XY) — primary service condition	LPBF SA + double-age (Z)
Elastic modulus	—	197–217 GPa	—
Yield strength (0.2%)	700–870 MPa	793–1000 MPa	780–950 MPa
Ultimate tensile strength	960–1150 MPa	1207–1380 MPa	1160–1320 MPa
Elongation at break	12.0–28.0 %	12.0–28.0 %	10.0–26.0 %
Hardness (HV)	—	365–430 HV10	—
Fatigue strength	—	500–690 MPa	—
Density	8.19 g/cm³	—	—
Thermal conductivity	11.7 W/m·K	—	—
CTE	12.8–14.2 µm/m·K	—	—
Max service temperature	—	870 °C	—

Values shown as min–max where a spread is reported, otherwise as typical ± unit. Ranges reflect inter-source variation, not single-sample scatter. All values are for AM-processed specimens unless noted.

Engineering considerations

Hot-cracking mitigation strategy: (1) elevated preheat 200–400°C reduces thermal gradient; (2) island scan strategy reduces thermal accumulation; (3) low VED reduces heat input per unit volume; (4) support strategy that limits constraint at high-stress locations. Even with mitigations, 100% FPI + CT inspection of every Waspaloy part is strongly recommended before heat treatment.
Heat treatment control: solution anneal at 1080°C ±10°C for exactly 4h is critical. Under-annealing (< 4h or < 1070°C) leaves primary γ' undissolved, reducing subsequent ageing response. Over-annealing (> 1100°C or > 6h) causes grain coarsening. Use vacuum or Ar atmosphere.
Cracking detection: fluorescent penetrant inspection (FPI per ASTM E1417) after machining. Industrial CT scanning (0.1 mm resolution or better) is preferred for complex internal features. Do not accept parts with cracks > 0.5 mm before heat treatment.
Comparison with IN718: choose Waspaloy when service temperature > 650°C and creep/fatigue governs design. Below 650°C, IN718 provides equivalent or better properties with lower processing risk and cost. If design allows downgrading from 850°C to 700°C service, IN718 may be substituted at significant cost and risk reduction.
Alloy stability: γ' coarsening rate increases sharply above 870°C. If temperature excursions above 870°C are possible in service, use a more stable alloy (René 88DT, IN939, CMSX-4) or account for γ' coarsening in life prediction.
Surface treatment: as-built LPBF surfaces have Ra 10–20 µm — unacceptable for rotating disc faying surfaces (require Ra < 1.6 µm per most aerospace standards). Plan for full machining of all functional surfaces. Electropolishing or grit blasting for non-machined surfaces before coating.
Powder reuse: Waspaloy powder is susceptible to Al/Ti oxidation during LPBF processing. Characterise each reuse lot for chemistry (ICP-OES) and morphology (ASTM F3049). Limit reuse to 10 cycles or less; recalibrate oxygen content after each cycle.

Advantages

Outstanding combination of creep strength and fatigue resistance at 700–870°C — surpasses IN718 above 650°C
γ' precipitation strengthening provides superior strength retention at high temperature vs. solid-solution alloys
Good oxidation resistance to ~1000°C in air and combustion gases
LPBF enables complex internal cooling passages for compressor disc cooling — not achievable in forging
Established wrought property database (AMS 5544) provides design baseline for LPBF qualification
No Laves phase issues (unlike IN718) — no Nb-rich eutectic segregation during solidification

Limitations

High hot-cracking susceptibility in LPBF — high (Al+Ti) content drives γ' precipitation during layer reheating, causing strain-age cracking (SAC)
Requires elevated preheat (200–400°C) and tightly controlled scan strategy — significantly higher LPBF complexity than IN718
Limited LPBF parameter databases — fewer published studies vs. IN718 or IN625; higher parameter development investment needed
Mandatory full heat treatment (SA + double-age) — complex 3-step process with tight temperature control (±10°C)
Residual microcracking is difficult to detect without CT or FPI — quality assurance cost is high
Very high powder cost (premium Ni superalloy with Co) — 2–3× more expensive than IN718 powder
Restricted to LPBF — DED is theoretically possible but cracking risk is higher due to lower cooling rates
Hot-cracking risk is exacerbated by high build temperatures — careful thermal management during build is essential

Typical applications

Gas turbine compressor discs and impellers — primary application exploiting high fatigue strength at 700–870°CTurbine disc bores and bolt holes — where fatigue crack initiation is criticalCompressor rotor blades — stationary and rotatingHigh-temperature fasteners and bolts for gas turbine assembliesCombustion casing components operating at intermediate temperaturesIndustrial gas turbine hot section componentsRocket engine turbopump components operating at cryogenic-to-hot cycle conditions

Standards & certifications

ASTM-F3049established

Powder feedstock characterisation for LPBF Waspaloy

aerospaceenergy

No dedicated AM Waspaloy standard. Aerospace qualification follows OEM-specific plans. AMS 5544 (wrought) used as property benchmark.

AMS-7000established

LPBF process requirements for aerospace applications

aerospacedefence

NADCAP-AC7110-14established

NADCAP accreditation for metallic AM parts — required for aerospace flight-critical Waspaloy parts

aerospace

Waspaloy®

Composition — UNS N07001 / ASTM B637 / AMS 5544

Mechanical & thermal properties — 3 conditions

Engineering considerations

Advantages

Limitations

Typical applications

Industries

Standards & certifications

Compatible AM processes (1)

Other metal materials

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