Hastelloy X Powder for Additive Manufacturing (3D Printing)

Post Processing of Additively Manufactured Hastelloy X Parts

After printing, Hastelloy X parts must undergo the following post processing steps before putting into service:

Support Removal

• Sacrificial supports are detached using wire EDM cutting or chemical dissolution where accessible.

Stress Relieving

• To eliminate residual stresses from the layerwise buildup, heat gently under vacuum or inert gas to 760-980°C for 1-2 hours.

Hot Isostatic Pressing

• HIP the entire print at 1120°C temperature and 100-200 MPa pressure for 3-6 hours to close internal voids and microporosity.

Heat Treatment

• Solution annealing between 1150-1210°C ensures equilibrium microstructure and desired hardness.

Surface Processing

• Additional surface treatments involve grinding, milling, polishing and shot peening to attain required surface roughness and finish.

Quality Testing

• Test parts meet specifications for dimensions, material integrity, microstructure and mechanical properties per applicable standards. Conduct layerwise scanning.

Buyer’s Guide – Hastelloy X Powder Bed 3D Printers

Critical printer considerations for working with reactive alloys like Hastelloy X powder include:

Precision – tight process controls for dimensional accuracy and repeatability over builds

Inert Atmosphere – very high purity shielding gas to prevent material contamination

Automation – powder handling systems to minimize oxygen exposure

Quality Assurance – inline monitoring, closed loop feedback of melt pools and microstructure

Smart Software – special scanning strategies adapting to thermal history and geometry

Productivity – faster build rates through higher laser power and large build volumes

Leading models include:

• 3D Systems DMP Factory 500
• GE Additive Concept Laser Xline 2000R
• EOS M 400-4 4-laser system
• SLM Solutions Next Generation series
• Renishaw RenAM 500 Quad laser machine

Future Outlook for Hastelloy X and Metal AM

The applications for Hastelloy X components will expand within existing sectors as additive techniques enable newer possibilities combined with increasing economic viability:

• More common use directly 3D printing rocket combustion chambers, commercial jet engine parts, industrial gas turbine hot sections and power generation hardware given enhanced geometric, cooling and weight benefits.
• Additional chemical equipment like heat exchanger internals and process tanks with conformal channels printed as one body rather than welded sheet metal assemblies.
• Consolidating module assemblies and traditionally brazed joints for aerospace and semiconductor production equipment susceptible to vacuum and high purity corrosive atmospheres.
• Customized, unitized fuel injector assemblies and effusion cooling plates tailored to specific thermal environments in liquid propulsion systems and turbines.
• Increased adoption of patient matched implants like dental bridges and crowns taking advantage of biocompatibility.

The future of metal AM itself is very positive due to greater affordability along with faster build rates and turnaround times. Manufacturing applications of the technology keep expanding.

FAQs

Q: What is Hastelloy X most known for regarding its alloy properties?

A: Hastelloy X is most renowned for retaining high strength at extreme temperatures up to 1150°C along with superb corrosion resistance allowing it to endure hot oxidizing and reducing atmospheres in demanding environments.

Q: What industries use Hastelloy X and its related superalloys the most?

A: Aerospace is the leading consumer of Hastelloy X exploiting its heat resistance – over 50% usage. Next is chemical processing relying on corrosion resistance, followed by metal processing and pollution control applications.

Q: What makes Hastelloy X better than other Ni-based superalloys for extreme environments?

A: Strategic additions of iron, cobalt and molybdenum give Hastelloy X the highest strength among nickel alloys up to 1150°C. Other Ni superalloys either fall short of this max temperature or eventually get outperformed in rupture strength duration.

Q: What is the typical cost per kg of Hastelloy X powder suitable for AM powder bed processes?

A: Because Hastelloy X is a specialty powder tailored to demanding applications, its pricing ranges from $500 to $1000 per kg normally. This is 5-10X stainless steel costs for example. There is further markup for lower quantity orders.

Q: Which 3D printing process works better for Hastelloy X – DMLS or EBM?

A: Both LPBF and EBM can print fully dense Hastelloy X components. Laser based processes may offer better surface finish and dimensional precision down to ~50 microns detail. But EBM’s faster build rate makes it preferred for higher volume production applications.

Q: What heat treatment is used for Hastelloy X parts after metal AM construction?

A: The typical heat treatment cycle involves 1-2 hours of soaking between 1150°C to 1210°C after a 1080°C stress relief first. This homogenizes elements in the matrix providing desired phase balance and properties.

Q: Is Hastelloy X harder or easier to machine than standard 304 or 316 stainless steel grades?

A: Hastelloy X has nearly 50% lower machinability rating relative to common 300 series stainless steels because of its higher strength and work hardening characteristics. More rigid setups and appropriate tooling required.

Q: Can you weld Hastelloy X superalloy using conventional fusion welding methods?

A: Yes, Hastelloy X shows excellent weldability via gas tungsten arc welding (GTAW), plasma or laser beam techniques owing to low carbon and absence of strengthening precipitates along grain boundaries that can form brittle intermetallic phases. Use matching filler alloy.

Q: What industries will drive future adoption of metal AM using alloys like Hastelloy X?

A: Aerospace, medical, automotive and energy industries have some of the highest value applications for printed metal parts made from alloys which balance properties like temperature resistance, corrosion resistance and high strength where lightweight constructions confer significant benefits.