K438(IN738) Ni-based superalloy is a typical aerospace superalloy, but it has a high sensitivity of printing cracking that limits the application of those parts additively manufactured by such alloy in the aerospace field. We conducted the high-throughput design, optimization and manufacturing based on the K438 alloy composition and finally successfully inhibited the phenomenon of printing cracking. Additionally, the alloy powder has a wide process window of crack-free printing, which can realize the stable printing of complex structural parts. The as-printed sample exhibits a tensile yield strength of 850-950 MPa, an ultimate tensile strength of 1250-1450 MPa MPa, and an elongation of 23-39%. The heat-treated sample exhibits a tensile yield strength of 890-1120 MPa, an ultimate tensile strength of 1340-1570 MPa, and an elongation of 9-22%.
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