Microstructure and mechanical response of as-built and solution-annealed LPBF Hastelloy X under high-temperature fatigue loading

This study investigates the microstructural characteristics and the high-temperature mechanical behavior of Hastelloy X, fabricated via laser powder-bed fusion (LPBF) technology. Hastelloy X, a solid solution-strengthened nickel-based superalloy known for its high strength and oxidation resistance at elevated temperatures, has gained significant interest for the fabrication of complex aerospace components through LPBF technology. The study initially focuses on the impact of solution annealing heat treatment at 1227 °C on the alloy microstructure, based on scanning electron microscopy (SEM) and transmission electron microscopy (TEM) investigations. It then explores the fatigue and cyclic deformation response of the alloy at 750 °C across different strain ranges, comparing the as-built and solution-annealed conditions. To understand the observed differences in the cyclic mechanical response of as-built and solution-annealed LPBF HX, for a particular condition, a set of dedicated tests have been performed and interrupted at selected numbers of cycles in the different stages of the mechanical response. At each interruption point, specimens have been examined by TEM to provide an in-depth understanding of the effect of dislocation microstructural evolution on the high-temperature cyclic mechanical response of the alloy.