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

Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
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.
Powder bed fusion, Nickel-based superalloy, Hastelloy X, Cracking, Nanoparticle
2214-8604
Han, Quanquan
50c274a8-a7a1-458c-91d0-e21425824753
Gu, Yuchen
dce760ae-1f4d-4dd2-8d9d-fc7e7904424c
Setchi, Rossitza
39fd58ce-d4f5-42a2-959e-0ee4324c4424
Lacan, Franck
d6010826-b1a4-444e-b551-b794f2bbdfdc
Johnston, Richard
79a1a026-0182-4843-961c-f729793f9b4f
Evans, Sam L.
962f93bd-5378-4002-aeef-787a5dee2f4c
Yang, Shoufeng
e0018adf-8123-4a54-b8dd-306c10ca48f1
Han, Quanquan
50c274a8-a7a1-458c-91d0-e21425824753
Gu, Yuchen
dce760ae-1f4d-4dd2-8d9d-fc7e7904424c
Setchi, Rossitza
39fd58ce-d4f5-42a2-959e-0ee4324c4424
Lacan, Franck
d6010826-b1a4-444e-b551-b794f2bbdfdc
Johnston, Richard
79a1a026-0182-4843-961c-f729793f9b4f
Evans, Sam L.
962f93bd-5378-4002-aeef-787a5dee2f4c
Yang, Shoufeng
e0018adf-8123-4a54-b8dd-306c10ca48f1

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

Record type: Article

Abstract

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.

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More information

Accepted/In Press date: 14 October 2019
e-pub ahead of print date: 15 October 2019
Published date: 1 December 2019
Keywords: Powder bed fusion, Nickel-based superalloy, Hastelloy X, Cracking, Nanoparticle

Identifiers

Local EPrints ID: 437142
URI: http://eprints.soton.ac.uk/id/eprint/437142
ISSN: 2214-8604
PURE UUID: 611210ee-3a44-49a1-ba7e-581fe77a1ada
ORCID for Shoufeng Yang: ORCID iD orcid.org/0000-0002-3888-3211

Catalogue record

Date deposited: 17 Jan 2020 17:36
Last modified: 09 Nov 2021 16:30

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Contributors

Author: Quanquan Han
Author: Yuchen Gu
Author: Rossitza Setchi
Author: Franck Lacan
Author: Richard Johnston
Author: Sam L. Evans
Author: Shoufeng Yang ORCID iD

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