Increasing productivity of laser powder bed fusion manufactured Hastelloy X through modification of process parameters

One of the factors limiting use additive manufacturing, particularly powder bed processes, is their low productivity. An approach to increasing laser fusion (LPBF) build rate without costly hardware modifications alter process parameters. This study evaluates possibilities increase rates through this route compromising material quality. Equations for productivity are derived based on parameters and geometry, applied window Hastelloy X in LPBF. It demonstrated that virtually flaw-free parts can be printed at differ up tenfold. To investigate potential variations microstructure performance, specimens manufactured varying were characterized. Electron backscattered diffraction (EBSD) analysis revealed specimen built lowest shows strong texture with columnar grains, while highest presents significantly more random orientation evident melt pool contours pockets very fine grains bottom. Despite major differences microstructure, tensile properties do not necessarily vary substantially. Thus, results indicate LPBF varied parameters, still yielding consistent mechanical properties.