Non-weldable materials such as various Ni-based superalloys have high thermomechanical properties and good corrosion resistance at high temperatures [1]. However, standard additive manufacturing processes, such as PBF, are not yet suitable for difficult and non-weldable alloys due to their poor weldability [2-4]. Therefore, fused filament fabrication (FFF) is used in this article to produce complex components from a non-weldable Ni-based superalloy. For this purpose, the alloy MAR-m247 is investigated. The elimination of the high cracking susceptibility of MAR-m247 during filament fabrication and the sinter-based FFF process is emphasised.

The fabrication of highly filled filaments with 94 wt.% of metal is described. The effects of process parameters, debinding and sintering on the tensile strength and fatigue behavior at room and high temperatures are discussed. The microstructure of the sintered specimens after post-heat treatment was investigated by electron microscopy. The porosity in the sintered specimens is less than 2%, while the total shrinkage is about 14 %.