Tensile and High Cycle Fatigue Performance at Room and Elevated Temperatures of Laser Powder Bed Fusion Manufactured Hastelloy X

Abstract

The application potential of additive manufacturing nickel-based superalloys in aeroengines and gas turbines is extensive, and evaluating their mechanical properties is crucial for promoting the engineering application in load-bearing components. In this study, Hastelloy X alloy was prepared using the laser powder bed fusion process combined with solution heat treatment. The tensile and high cycle fatigue properties were experimentally investigated at room temperature as well as two typical elevated temperatures, 650 °C and 815 °C. It was found that, during elevated-temperature tensile deformation, the alloy exhibits significant serrated flow behavior, primarily observed during the initial stage of plastic deformation at 650 °C but occurring throughout the entire plastic deformation process at 815 °C. Notably, when deformation is small, sawtooth fluctuations are significantly higher at 815 °C compared to 650 °C. Irregular subsurface lack of fusion defects serve as primary sources for fatigue crack initiation in this alloy including both single-source and multi-source initiation mechanisms; moreover, oxidation on fracture surfaces is more prone to occur at elevated temperatures, particularly at 815 °C.