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Fusion-Based Additive Manufacturing of Hastelloy C-Series: A Comparative Study on Microstructure, Mechanical Properties, and Residual Stress

Year: 2025

Type: article

Abstract: The fusion-based single pulsed gas metal arc welding (SP-GMAW) additive manufacturing (AM) process has attracted considerable attention because of its high production efficiency, elevated deposition rates, and near-net-shape capabilities. The present study presents a comparative investigation of Hastelloy C-276 and Hastelloy C-22 thin-walled components fabricated using a SP-GMAW based AM process. This study thoroughly investigates the microstructure, material properties, and residual stress of the components. The microstructures in various regions comprise dendrite structure in Hastelloy C-276 and C-22 superalloys. The Scanning Electron Microscopy and Energy Dispersive Spectroscopy (SEM/EDS) analysis revealed a discrepancy in elemental composition between C-276 and C-22 materials. Additionally, the average grain size in the top, middle, and bottom portions of C-22 are$67.8~\mu $m,$78.6~\mu $m, and$87.6~\mu $m while C-276 has$72.5~\mu $m,$80.2~\mu $m, and$96.8~\mu $m, respectively. Compared to the build direction, the travel direction has a higher mean microhardness. Hastelloy C-22 achieves a maximum hardness of 320 HV, while Hastelloy C-276 has a hardness of 286 HV. The highest recorded tensile strength for Hastelloy C-22 was$772~\pm ~5.1$MPa, whereas Hastelloy C-276 displayed a tensile strength of$758~\pm ~4.1$MPa in the upper regions along the travel direction. According to the stress distribution, the as-fabricated specimens of Hastelloy C-276 and C-22 are mostly impacted by tensile residual stress. Research on Hastelloy C series alloy comparisons and single pulsed GMAW-based WAAM technologies is limited and progressing. The comparative results of this research will be significant in the chemical-based, nuclear energy, maritime, and manufacturing industries.

Source: IEEE Access

DOI: 10.1109/access.2025.3598731