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Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy

Han, Quanquan, Gu, Yuchen, Setchi, Rossitza ORCID:, Lacan, Franck ORCID:, Johnston, Richard, Evans, Sam L. ORCID: and Yang, Shoufeng 2019. Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy. Additive Manufacturing 30 , 100919. 10.1016/j.addma.2019.100919

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Laser powder bed fusion (LPBF) is a proven additive manufacturing (AM) technology for producing metallic components with complex shapes using layer-by-layer manufacture principle. However, the fabrication of crack-free high-performance Ni-based superalloys such as Hastelloy X (HX) using LPBF technology remains a challenge because of these materials’ susceptibility to hot cracking. This paper addresses the above problem by proposing a novel method of introducing 1 wt.% titanium carbide (TiC) nanoparticles. The findings reveal that the addition of TiC nanoparticles results in the elimination of microcracks in the LPBF-fabricated enhanced HX samples; i.e. the 0.65% microcracks that were formed in the as-fabricated original HX were eliminated in the as-fabricated enhanced HX, despite the 0.14% residual pores formed. It also contributes to a 21.8% increase in low-angle grain boundaries (LAGBs) and a 98 MPa increase in yield strength. The study revealed that segregated carbides were unable to trigger hot cracking without sufficient thermal residual stresses; the significantly increased subgrains and low-angle grain boundaries played a key role in the hot cracking elimination. These findings offer a new perspective on the elimination of hot cracking of nickel-based superalloys and other industrially relevant crack-susceptible alloys. The findings also have significant implications for the design of new alloys, particularly for high-temperature industrial applications.

Item Type: Article
Date Type: Publication
Status: Published
Schools: Engineering
Publisher: Elsevier
ISSN: 2214-7810
Date of First Compliant Deposit: 16 October 2019
Date of Acceptance: 14 October 2019
Last Modified: 18 Nov 2023 07:47

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