On direct laser deposited Hastelloy X: dimension, surface finish, microstructure and mechanical properties

For the first time, the influence of laser power, scan speed, scan spacing and nominal laser power density on the tensile properties, dimensional accuracy, surface roughness, number of cracks and top surface concavity of samples of Hastelloy X manufactured using a laser powder bed facility, has been assessed systematically on three-dimensional samples. It has been found that the nominal laser power density is the dominant factor, but the influence of scan spacing and scan speed can sometimes be significant. Density of > 99.5% can be obtained using most conditions. Cracks are observed at corners of the samples. An optimised process window can be derived from the above systematic analysis under which the component can be built smoothly, with good surface finish and dimensional accuracy, consistent mechanical properties and the properties are comparable with those of forged products.