Abstract: In this study, a novel Ni-based superalloy, ZGH451, has been fabricated using direct energy deposition (DED). The thermal fatigue resistance of ZGH451 is systematically evaluated at 900, 1000, and 1100 °C, primarily focusing on the crack initiation and propagation behaviors. The results indicate that higher peak temperatures lead to earlier initiation and more rapid propagation of cracks. Cracks are initiated at the defects and grain boundaries in the vicinity of the notch, and different crack propagation mechanisms (γ' phase slip shearing, γ' phase distortion shearing, and γ' phase rafting shearing at 900, 1000, and 1100 °C, respectively) are the main reason for the different cracks propagation behaviors under the three temperatures. The main crack propagation paths are oriented at approximately 45° with respect to the build direction, suggesting activation of the {111}<110> slip system. Additionally, oxidation reduces the matrix strength and passivates the crack tips, leading to varying rates of crack propagation. At elevated temperatures, the synergistic effects of thermal stress and oxidative erosion are found to be the primary damage mechanisms of thermal fatigue. Overall, the proposed ZGH451 superalloy demonstrates exceptional thermal fatigue resistance, providing a crucial experimental reference for thermal fatigue in additively manufactured superalloys.

Key words: Direct energy deposition, Thermal fatigue, Crack initiation and propagation, Ni-based superalloy