Investigation into Mechanical Properties and Microstructure of Heat-Treated Hastelloy-X Thin Wall Specimens Obtained by Laser Powder Bed Fusion

This paper investigates how the thickness of dogbone tensile specimens made from heat-treated Hastelloy-X alloy produced by Laser Powder Bed Fusion (LPBF) influences their mechanical properties and microstructure. The focus of the investigation is on surfaces in an “as-built” condition and considers a range of thickness from 3 to 1 mm. The “as-built” surfaces condition is a fundamental outcome, considering that LPBF technology’s key feature is the ability to produce intricate and complex geometries that are difficult to achieve with conventional manufacturing technologies. The specimens were fabricated according to ASTM E8/E8M-21 and were heat-treated in a vacuum furnace at 1150 °C for two hours. The microstructure of the material was evaluated through porosity, EBSD, and Microhardness analyses. The mechanical properties were evaluated through tensile tests conducted at room temperature on dogbone specimens fabricated both parallel and perpendicular to the building direction. The findings indicate a significant reduction in mechanical properties that could be correlated with the reduction in specimen thickness, reflecting a gradual decline from the baseline. Specifically, a 14% decrease in Ultimate Tensile Strength (from 612 to 528 MPa), an approximately 19% reduction in Young’s Modulus (from 190 GPa to 153 GPa), and a 32% decrease in Elongation at Break (from 59.2% to 40.0%) were observed. Furthermore, it was noted that the printing orientation of the specimens significantly affects their mechanical properties, regardless of thickness. Overall, the results suggest that applying standard heat treatment under specific conditions, such as with a thin, exposed wall of about 1mm with a striped strategy, may not lead to adequate material performance.