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Epitaxial Growth in Additive Manufacturing of High-$\gamma'$ Nickel-based Superalloys: Solidification Dynamics, Defect Mitigation, and Hybrid Synergy
Review Article | Published: 25 February 2026
Journal of Advanced Materials Research Volume 2, Issue 1, 2026: 55-85
Volume 2, Issue 1, Journal of Advanced Materials Research
Volume 2, Issue 1, 2026
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Journal of Advanced Materials Research, Volume 2, Issue 1, 2026: 55-85

Open Access | Review Article | 25 February 2026
Epitaxial Growth in Additive Manufacturing of High-$\gamma'$ Nickel-based Superalloys: Solidification Dynamics, Defect Mitigation, and Hybrid Synergy
by
Anhui Xiong Anhui Xiong 1,†
Xianghui Wang Xianghui Wang 1,†
Pan Ying Pan Ying 1,†
Chen Chang Chen Chang 1
Ze Li Ze Li 1
Dong Zheng Dong Zheng 1
Shuang Shi Shuang Shi 1
Yang Chen Yang Chen 1,2 *
1 State Key Laboratory of Advanced Casting Technologies, Nanjing University of Science and Technology, Nanjing 210094, China
2 State Key Laboratory of light superalloys, Henan University of Science and Technology, Luoyang 471023, China
† These authors contributed equally to this work
* Corresponding Author: Yang Chen, [email protected]
DOI: 10.62762/JAMR.2025.827155
ARK: ark:/57805/jamr.2025.827155
Received: 11 December 2025, Accepted: 11 February 2026, Published: 25 February 2026  
   PDF  (2.48 MB)
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Abstract
Additive manufacturing (AM) is redefining the limits of directional solidification (DS) and single-crystal (SX) fabrication for nickel-based superalloys. By reconciling classical Bridgman theory with the extreme thermal gradients (G) and solidification velocities (V) inherent to AM, this review establishes a unified framework for controlled epitaxy. It dissects the kinetics of grain competition and the columnar-to-equiaxed transition (CET), highlighting how scan strategies and thermal management dictate melt pool geometry and the G/V ratio. A comparative assessment of laser powder bed fusion (L-PBF), electron beam powder bed fusion (EB-PBF), and directed energy deposition (DED) delineates distinct process windows for direct fabrication versus epitaxial repair. Addressing the conflict between printability and performance in high-$\gamma'$ alloys, the text links defect mechanisms, specifically stray grains (SGs) driven by constitutional supercooling, complex cracking modes, and surface anomalies, to targeted mitigation strategies ranging from virtual grain selection to alloy tailoring and synergistic post-processing. Ultimately, a multi-process hybrid architecture is proposed that positions EB-PBF as the foundational platform for bulk SX formation, augmented by L-PBF or DED, to close the "manufacture–service–repair–remanufacture" engineering loop.
Graphical Abstract
Epitaxial Growth in Additive Manufacturing of High-$\gamma'$ Nickel-based Superalloys: Solidification Dynamics, Defect Mitigation, and Hybrid Synergy
Keywords
additive manufacturing
superalloys
single crystal
directional solidification
Data Availability Statement
Not applicable.
Funding
This work was supported in part by the National Natural Science Foundation of China under Grant 52202049; in part by the Fundamental Research Funds for the Central Universities under Grant 30924010206; in part by the Advanced Materials-National Science and Technology Major Project under Grant 2025ZD0608601.
Conflicts of Interest
The authors declare no conflicts of interest.
AI Use Statement
The authors declare that no generative AI was used in the preparation of this manuscript.
Ethical Approval and Consent to Participate
Not applicable.
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Xiong, A., Wang, X., Ying, P., Chang, C., Li, Z., Zheng, D., Shi, S., & Chen, Y. (2026). Epitaxial Growth in Additive Manufacturing of High-γ' Nickel-based Superalloys: Solidification Dynamics, Defect Mitigation, and Hybrid Synergy. Journal of Advanced Materials Research, 2(1), 55–85. https://doi.org/10.62762/JAMR.2025.827155
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TY  - JOUR
AU  - Xiong, Anhui
AU  - Wang, Xianghui
AU  - Ying, Pan
AU  - Chang, Chen
AU  - Li, Ze
AU  - Zheng, Dong
AU  - Shi, Shuang
AU  - Chen, Yang
PY  - 2026
DA  - 2026/02/25
TI  - Epitaxial Growth in Additive Manufacturing of High-$\gamma'$ Nickel-based Superalloys: Solidification Dynamics, Defect Mitigation, and Hybrid Synergy
JO  - Journal of Advanced Materials Research
T2  - Journal of Advanced Materials Research
JF  - Journal of Advanced Materials Research
VL  - 2
IS  - 1
SP  - 55
EP  - 85
DO  - 10.62762/JAMR.2025.827155
UR  - https://www.icck.org/article/abs/JAMR.2025.827155
KW  - additive manufacturing
KW  - superalloys
KW  - single crystal
KW  - directional solidification
AB  - Additive manufacturing (AM) is redefining the limits of directional solidification (DS) and single-crystal (SX) fabrication for nickel-based superalloys. By reconciling classical Bridgman theory with the extreme thermal gradients (G) and solidification velocities (V) inherent to AM, this review establishes a unified framework for controlled epitaxy. It dissects the kinetics of grain competition and the columnar-to-equiaxed transition (CET), highlighting how scan strategies and thermal management dictate melt pool geometry and the G/V ratio. A comparative assessment of laser powder bed fusion (L-PBF), electron beam powder bed fusion (EB-PBF), and directed energy deposition (DED) delineates distinct process windows for direct fabrication versus epitaxial repair. Addressing the conflict between printability and performance in high-$\gamma'$ alloys, the text links defect mechanisms, specifically stray grains (SGs) driven by constitutional supercooling, complex cracking modes, and surface anomalies, to targeted mitigation strategies ranging from virtual grain selection to alloy tailoring and synergistic post-processing. Ultimately, a multi-process hybrid architecture is proposed that positions EB-PBF as the foundational platform for bulk SX formation, augmented by L-PBF or DED, to close the "manufacture–service–repair–remanufacture" engineering loop.
SN  - 3070-5851
PB  - Institute of Central Computation and Knowledge
LA  - English
ER  -
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@article{Xiong2026Epitaxial,
  author = {Anhui Xiong and Xianghui Wang and Pan Ying and Chen Chang and Ze Li and Dong Zheng and Shuang Shi and Yang Chen},
  title = {Epitaxial Growth in Additive Manufacturing of High-\$\gamma'\$ Nickel-based Superalloys: Solidification Dynamics, Defect Mitigation, and Hybrid Synergy},
  journal = {Journal of Advanced Materials Research},
  year = {2026},
  volume = {2},
  number = {1},
  pages = {55-85},
  doi = {10.62762/JAMR.2025.827155},
  url = {https://www.icck.org/article/abs/JAMR.2025.827155},
  abstract = {Additive manufacturing (AM) is redefining the limits of directional solidification (DS) and single-crystal (SX) fabrication for nickel-based superalloys. By reconciling classical Bridgman theory with the extreme thermal gradients (G) and solidification velocities (V) inherent to AM, this review establishes a unified framework for controlled epitaxy. It dissects the kinetics of grain competition and the columnar-to-equiaxed transition (CET), highlighting how scan strategies and thermal management dictate melt pool geometry and the G/V ratio. A comparative assessment of laser powder bed fusion (L-PBF), electron beam powder bed fusion (EB-PBF), and directed energy deposition (DED) delineates distinct process windows for direct fabrication versus epitaxial repair. Addressing the conflict between printability and performance in high-\$\gamma'\$ alloys, the text links defect mechanisms, specifically stray grains (SGs) driven by constitutional supercooling, complex cracking modes, and surface anomalies, to targeted mitigation strategies ranging from virtual grain selection to alloy tailoring and synergistic post-processing. Ultimately, a multi-process hybrid architecture is proposed that positions EB-PBF as the foundational platform for bulk SX formation, augmented by L-PBF or DED, to close the "manufacture–service–repair–remanufacture" engineering loop.},
  keywords = {additive manufacturing, superalloys, single crystal, directional solidification},
  issn = {3070-5851},
  publisher = {Institute of Central Computation and Knowledge}
}
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