Mechanical properties of Hastelloy X produced by laser powder bed fusion and affected by spatter redeposition

Journal article, 2024

Defects in materials manufactured via laser powder bed fusion challenge this manufacturing process' dependability and may prevent it from being comprehensively used for structural components, particularly those intended to operate under dynamic loading conditions. This study aims to investigate the effect of spatter-driven lack of fusion on the mechanical properties of Hastelloy X, with a particular focus on fatigue performance. Mechanical test specimens were manufactured in two builds with different build rates and monitored through in-situ optical tomography. The images acquired in situ were analyzed to detect spatter redeposits to predict the defect content in the gauge section. Selected specimens were measured ex-situ using X-ray computed tomography to map the defect populations. Afterward, the specimens were tensile and fatigue tested, and their performance was analyzed based on the measured and expected defect populations. It was confirmed that a higher build rate is associated with more extensive detection of spatter redeposits in optical tomography images and lack of fusion defects. The fatigue lives of specimens manufactured at higher build rates presented higher scatter but significantly higher average, despite the more critical defect population. Surprisingly, the confirmed presence of lack of fusion defects in the gauge section of test specimens did not necessarily result in a poorer fatigue performance. It was concluded that the grain refinement obtained through the increase in nominal layer thickness has a life-prolonging effect that overrides the effects of spatter-induced lack of fusion defects.