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

Quanquan Han, Yuchen Gu, Rossitza Setchi, Franck Lacan, Richard Johnston Orcid Logo, Sam L. Evans, Shoufeng Yang

Additive Manufacturing, Volume: 30, Start page: 100919

Swansea University Author: Richard Johnston Orcid Logo

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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 technol...

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Published in: Additive Manufacturing
ISSN: 2214-8604
Published: Elsevier BV 2019
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URI: https://cronfa.swan.ac.uk/Record/cronfa52481
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spelling 2019-10-17T10:43:11.7101547 v2 52481 2019-10-17 Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy 23282e7acce87dd926b8a62ae410a393 0000-0003-1977-6418 Richard Johnston Richard Johnston true false 2019-10-17 MTLS 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. Journal Article Additive Manufacturing 30 100919 Elsevier BV 2214-8604 Powder bed fusion, nickel-based superalloy, Hastelloy X, cracking, nanoparticle 31 12 2019 2019-12-31 10.1016/j.addma.2019.100919 COLLEGE NANME Materials Science and Engineering COLLEGE CODE MTLS Swansea University 2019-10-17T10:43:11.7101547 2019-10-17T10:32:02.9584742 College of Engineering Engineering Quanquan Han 1 Yuchen Gu 2 Rossitza Setchi 3 Franck Lacan 4 Richard Johnston 0000-0003-1977-6418 5 Sam L. Evans 6 Shoufeng Yang 7 0052481-17102019104224.pdf han2019.pdf 2019-10-17T10:42:24.2000000 Output 5259893 application/pdf Accepted Manuscript true 2020-10-15T00:00:00.0000000 © 2019. This manuscript version is made available under the CC-BY-NC-ND 4.0 license true eng http://creativecommons.org/licenses/by-nc-nd/4.0/
title Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
spellingShingle Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
Richard, Johnston
title_short Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
title_full Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
title_fullStr Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
title_full_unstemmed Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
title_sort Additive manufacturing of high-strength crack-free Ni-based Hastelloy X superalloy
author_id_str_mv 23282e7acce87dd926b8a62ae410a393
author_id_fullname_str_mv 23282e7acce87dd926b8a62ae410a393_***_Richard, Johnston_***_0000-0003-1977-6418
author Richard, Johnston
author2 Quanquan Han
Yuchen Gu
Rossitza Setchi
Franck Lacan
Richard Johnston
Sam L. Evans
Shoufeng Yang
format Journal article
container_title Additive Manufacturing
container_volume 30
container_start_page 100919
publishDate 2019
institution Swansea University
issn 2214-8604
doi_str_mv 10.1016/j.addma.2019.100919
publisher Elsevier BV
college_str College of Engineering
hierarchytype
hierarchy_top_id collegeofengineering
hierarchy_top_title College of Engineering
hierarchy_parent_id collegeofengineering
hierarchy_parent_title College of Engineering
department_str Engineering{{{_:::_}}}College of Engineering{{{_:::_}}}Engineering
document_store_str 1
active_str 0
description 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.
published_date 2019-12-31T04:18:19Z
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