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Nickel-based superalloys are used in high strength, high-value applications, such as gas turbine discs in aero engines. In these applications the integrity of the disc is critical and therefore understanding crack initiation mechanisms is of high importance. With an increasing trend towards powder metallurgy routes for discs, sometimes unwanted non-metallic inclusions are introduced during manufacture. These inclusions vary in size from ∼10 μm to 200 μm which is comparable to the grain size of the nickel-based superalloys. Cracks often initiate near these inclusions, and the precise size, shape, location and path of these cracks are microstructurally sensitive. In this study, we focus on crack initiation at the microstructural length scale using a controlled three-point bend test, with the inclusion deliberately located within the tensile fibre of the beam. Electron backscatter diffraction (EBSD) is combined with high spatial resolution digital image correlation (HR-DIC) to explore full field plastic strain distributions, together with finite element modelling, to understand the micro-crack nucleation mechanisms. This full field information and controlled sample geometry enable us to systematically test crack nucleation criteria. We find that a combined stored energy and dislocation density provide promising results. These findings potentially facilitate more reliable and accurate lifing prediction tools to be developed and applied to engineering components.

Advanced characterisation techniques were used on LPBF Ti-6Al-4V samples produced on a heated base plate. When the substrate temperature is 100°C the elongation is 6\%, which increases and peaks at 10\% at 570°C, then sharply decreases to zero ductility at 770°C. At 100°C, a heavily strained and twinned microstructure, primarily composed of {\alpha}+{\alpha}', was observed and it was comparable to asbuilt microstructures obtained by conventional LPBF methods. At higher temperatures, twins are no longer present and instead nano-scale {\beta} precipitates are observed within {\alpha}' and {\alpha}, as well as dislocation networks (570°C) and tangles (770°C). Solute segregation at crystal defects was observed in all pre-heating conditions. Al and V segregation at microtwins was observed in the 100°C sample, reporting for the first time `selective' and mutually exclusive Al- and V-rich regions forming in adjacent twins. V segregation at dislocations was observed in the 570°C and 770°C samples, consistent with the higher preheating temperatures. High O contents were measured in all samples but with apparent opposing effects. At 100°C and 570°C was estimated to be below the critical threshold for O embrittlement and locally aids in maintaining a strength high by solid solution strengthening, whereas at 770°C it was above the threshold, therefore failing in a brittle fashion. Based on these observations, the initial increase in ductility from 100°C to 570°C is attributed to a reduction in microtwins and the dislocation networks acting as `soft barriers' for slip within a coarser microstructure. The lack of ductility at 770°C was attributed to local solute redistribution causing dislocation pinning and an increase of O content in this sample.