Laser powder bed fusion of Hastelloy X: Effects of hot isostatic pressing and the hot cracking mechanism

Han, Quanquan; Mertens, Raya; Montero-Sistiaga, Maria L.; Yang, Shoufeng; Setchi, Rossitza; Vanmeensel, Kim; Hooreweder, Brecht Van; Evans, Samuel Lewin; Fan, Haiyang

doi:10.1016/j.msea.2018.07.008

Cited by 200 publications

(45 citation statements)

References 29 publications

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“…It should be noted that the opened pores exhibited irregular shapes rather than the circular shapes that were observed on the sectioned surface. The dendritic features were not observed in the fracture surfaces, which differs from the previous findings of a previous study on additive-manufactured HX alloys [11]. In that study, cleavage-like surfaces were observed, indicating that the columnar grains were elongated along the loading direction.…”

Section: Experimental Validationcontrasting

confidence: 99%

“…In that study, cleavage-like surfaces were observed, indicating that the columnar grains were elongated along the loading direction. This difference may be explained by the fact that the tensile samples were horizontally built in the present study (perpendicular to the loading direction), while the specimens used in [11] were fabricated vertically (parallel to the loading direction).…”

Section: Experimental Validationmentioning

confidence: 96%

“…Laser additive manufacturing (AM) is an established technology for the direct fabrication of metal components with complex geometries using layer-by-layer powder deposition and a high-power laser [1] [2] [3]. A wide range of metallic materials can be successfully processed using laser AM, including steel [4], titanium [5] [6], aluminium [7][8] [9], nickel [10] [11] and various composites. A variety of powder bed characteristics are critical to achieving a quality process because they affect the dimensional accuracy and structural integrity of the fabricated parts.…”

Section: Introductionmentioning

confidence: 99%

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Discrete element simulation of powder layer thickness in laser additive manufacturing

Han

Setchi

2019

Powder Technology

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The optimisation of the laser additive manufacturing (AM) process is a challenging task when a new material is considered. Compared to the selection of other process parameters such as laser power, scanning speed and hatch spacing, optimisation of powder layer thickness is much more time-consuming and costly because a new run is normally needed when the layer thickness value is changed. In practice, the layer thickness is fixed to a value that is slightly higher than the average particle size. This paper introduces a systematic approach to layer thickness optimisation based on a theoretical model of the interactions between the particles, the wiper and the build plate during the powder deposition. The focus is on a systematic theoretical and experimental investigation of the effect of powder layer thickness on various powder bed characteristics during single-layer and multi-layer powder deposition. The theoretical model was tested experimentally using Hastelloy X (HX) with an average particle size of 34.4 µm. The experimental results validated the simulation model, which predicted a uniform powder bed deposition when employing a 40 µm layer thickness value. Lower (30 µm) and higher (50 µm) layer thickness values resulted in large voids and short-feed defects, respectively. The subsequent optimisation of the scanning speed and hatch spacing parameters was executed using a 40 µm layer thickness. The optimum process parameters were then used to examine the microstructure and tensile performance of the as-fabricated HX. This study provides an improved understanding of the powder deposition process and offers insights into the selection of suitable powder layer thicknesses in laser AM.

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Section: Experimental Validationcontrasting

confidence: 99%

Section: Experimental Validationmentioning

confidence: 96%

Section: Introductionmentioning

confidence: 99%

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Discrete element simulation of powder layer thickness in laser additive manufacturing

Han

Setchi

2019

Powder Technology

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“…Additive manufacturing (AM), a rapidly developing and advanced manufacturing technology, provides an integrated way to fabricate three-dimensional complex-shaped components from computer-aided design models [7][8][9]. Among the most advanced AM technologies, selective laser melting (SLM) is a widely used process for manufacturing complex metallic parts [10][11][12]. Several recent studies have reported the microstructure and mechanical properties of SLM-fabricated AlSi10Mg alloys.…”

Section: Introductionmentioning

confidence: 99%

Effect of heat treatment and laser surface remelting on AlSi10Mg alloy fabricated by selective laser melting

Han

Jiao

2019

Int J Adv Manuf Technol

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100

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The selective laser melting (SLM) of aluminium alloys is of interest to researchers because of these alloys' potential applications in the aerospace and automotive domains. Post-processing is generally required in order to enhance the mechanical properties of devices that involve moving parts, where surface mechanical properties are significant factors. This paper describes a preliminary study that was conducted to investigate the effect of post-processing on the microstructure and mechanical properties of SLM fabricated AlSi10Mg alloy, with an emphasis on the laser surface remelting (LSR) process. The experimental results demonstrate that the heat treatment degraded tensile strength while improving ductility by achieving grain growth and residual stress release. The yield strength obtained in the experiment was reduced from 200 to 100 MPa, whereas the elongation increased from 6 to 22%. The LSR process was found to contribute to an improvement in surface finish. The surface roughness indicator R a was determined to be 0.93 μm in the LSR post-processed sample, compared to a fairly high value of 19.3 μm in the as-fabricated samples. The LSR process also enhanced the microhardness by refining the microstructure; the Si eutectic dendritic structure that formed was found to be finer than that of the as-fabricated samples. Compared to the as-fabricated samples, the LSR process contributed to a 19.5% increase in microhardness. The findings suggest that the microstructure and mechanical properties of SLM-fabricated AlSi10Mg parts could be tailored by suitable post-processing such as heat treatment and LSR. The significance of this research is its proposal of a novel technique to enhance surface hardness using LSR, which is a significant step towards the combination of SLM and LSR processes to manufacture customised aluminium components for the automotive and aerospace sectors.

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“…The selected material was Hastelloy C-22. This alloy presents excellent corrosion behavior as well as mechanical properties, being commonly employed in the industrial sectors [18][19][20][21][22][23]: Chemical, petrochemical, aerospace, etc.…”

Section: Introductionmentioning

confidence: 99%

Processing by Additive Manufacturing Based on Plasma Transferred Arc of Hastelloy in Air and Argon Atmosphere

Ariza

Arévalo

Montealegre-Meléndez

et al. 2020

Metals

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This research was carried out to determinate the effect of the atmosphere processing conditions (air and argon) and two specific thermal treatments, on the properties of specimens made from the nickel-based alloy Hastelloy C-22 by plasma transferred arc (PTA). Firstly, the additive manufacturing parameters were optimized. Following, two walls were manufactured in air and argon respectively. Afterwards, a determinate number of specimens were cut out and evaluated. Regarding the comparison performed with the extracted specimens from both walls, three specimens of each wall were studied as-built samples. Furthermore, a commonly used heat treatment in Hastelloy, with two different cooling methods, was selected to carry out additional comparisons. In this respect, six additional specimens of each wall were selected to be heat treated to a temperature of 1120 °C for 20 min. After the heat treatment, three of them were cooled down by rapid air cooling (RAC), while the other three were cooled down by water quenching (WQ). In order to study the influence degree of the processing conditions, and how the thermal treatments could modify the final properties of the produced specimens, a detailed characterization was performed. X-ray diffraction and microstructural analyses revealed the phases-presence and the apparition of precipitates, varying the thermal treatment. Moreover, the results obtained after measuring mechanical and tribological properties showed slight changes caused by the variation of the processing atmosphere. The yield strength of the extracted specimens from the two walls achieved values closer to the standards ones in air 332.32 MPa (±21.36 MPa) and in argon 338.14 MPa (±9 MPa), both without thermal treatment. However, the effect of the cooling rate resulted as less beneficial, as expected, reducing the deformation properties of the specimens below 11%, independently of the air or argon manufacturing atmosphere and the cooling rate procedure.

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Laser powder bed fusion of Hastelloy X: Effects of hot isostatic pressing and the hot cracking mechanism

Cited by 200 publications

References 29 publications

Discrete element simulation of powder layer thickness in laser additive manufacturing

Discrete element simulation of powder layer thickness in laser additive manufacturing

Effect of heat treatment and laser surface remelting on AlSi10Mg alloy fabricated by selective laser melting

Processing by Additive Manufacturing Based on Plasma Transferred Arc of Hastelloy in Air and Argon Atmosphere

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