At TCT Asia 2026, AVIMETAL introduced an integrated solution that addresses one of the most persistent challenges in metal additive manufacturing: the cracking of superalloys during laser powder bed fusion (LPBF). The MT-IN738 Superalloy Powder + Ring Beam LPBF Process combines an optimized nickel-based superalloy with an innovative beam shaping technology to enable reliable, high-quality production of aero engine and gas turbine hot-section components.

IN738 is a precipitation-strengthened nickel-based superalloy widely used in high-temperature applications due to its excellent creep resistance and corrosion properties. However, its susceptibility to cracking during LPBF has historically limited its adoption. AVIMETAL’s new integrated solution tackles this challenge from both the material and process perspectives, delivering a game-changing approach for the aerospace and energy industries.

Key Breakthroughs of the Integrated Solution

The MT-IN738 solution is built on two complementary pillars: an optimized superalloy powder produced with AVIMETAL’s proprietary AVI-VIGA technology, and an innovative ring beam LPBF process that fundamentally alters the melt pool dynamics.

Optimized Material Performance

The foundation of any reliable AM process is a high-quality powder. MT-IN738 has been specifically tailored for additive manufacturing:

• High Sphericity Powder: Produced using AVI-VIGA technology, the powder features a controlled particle size distribution of 15–53 μm, ensuring consistent layer spreading and melt behavior.

• Low Oxygen Content: With oxygen content below 200 ppm, the powder minimizes oxide formation that can act as crack initiation sites.

• Stable Composition: The alloy system is specifically designed for additive manufacturing, optimizing the balance of strengthening elements for LPBF processing.

• Excellent Flowability: Superior flow characteristics ensure stable recoating across the build plate, providing a foundational layer for effective crack suppression.

Innovative Ring Beam Process

The process innovation is centered around a ring beam laser profile, which replaces the conventional Gaussian beam to achieve fundamentally different melt pool behavior:

• Beam Conversion: The system seamlessly converts from a traditional 70 μm Gaussian beam to a 167 μm ring beam, dramatically widening the process window for IN738.

• Stable Melt Pool: The ring beam creates a more stable melt pool with reduced temperature gradients, resulting in >40% spatter reduction compared to conventional Gaussian processing.

• Crack Suppression: The combination of stable melt pool and reduced thermal stresses leads to significantly reduced crack density; importantly, no keyhole defects are observed.

• Efficiency Gain: The ring beam process is compatible with larger layer thicknesses, improving overall print efficiency without compromising quality.

Proven Results

The integrated solution has demonstrated clear performance advantages over conventional Gaussian beam processing:

• Surface Quality: Superior surface finish compared to parts produced with a standard Gaussian beam.

• Density: Excellent part density with a uniform, fine-grained microstructure.

• Process Window: A wider, more forgiving process window that enhances robustness and adaptability for production environments.

Typical Applications

The MT-IN738 integrated solution is specifically designed for components that must withstand extreme thermal and mechanical loads:

• Aero Engine Hot-Section Parts – Turbine blades, vanes, combustion chambers, and other components operating at elevated temperatures.

• Gas Turbine Blades and Nozzles – Power generation turbines requiring high creep resistance and thermal fatigue life.

• Complex Structures for High-Temperature Environments – Intricate cooling channel designs that were previously difficult to produce in crack-prone superalloys.

• Heat-Resistant Components for Energy Equipment – Industrial gas turbines, heat exchangers, and other high-temperature energy systems.

Compatible Printers

The MT-IN738 superalloy powder and ring beam LPBF process are supported across a range of AVIMETAL’s industrial platforms. The ring beam capability is available on systems equipped with adjustable beam shaping modules.

Compatible printers include:

• MT280 (with adjustable beam shaping module)

• MT400M

• MT450M

• MT650H

• Full series of compatible AVIMETAL LPBF systems

Conclusion

The introduction of the MT-IN738 Superalloy Powder + Ring Beam LPBF Process marks a significant advancement in the additive manufacturing of high-temperature superalloys. By addressing the fundamental cracking challenge through optimized powder and innovative beam shaping, AVIMETAL has delivered a solution that enables reliable, production-ready manufacturing of critical hot-section components for aero engines and gas turbines.

For manufacturers in aerospace, power generation, and energy sectors, this integrated approach opens new possibilities for complex, high-performance parts with the design freedom of additive manufacturing and the material integrity demanded by extreme environments.

Interested in learning how the MT-IN738 integrated solution can support your hot-section component production? Contact our team for technical data, process validation reports, or to discuss a trial on your AVIMETAL system.