Study of Additive Manufacturing of Hastelloy X Using Plasma Arc Welding Technology

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  • Plasma arc welding was implemented for additive manufacturing of Hastelloy X wire due to its potential to produce thin-wall structures for a high-temperature resistance of Hastelloy X. Single-layer beads were deposited to study and optimize the effects of arc length, nozzle size, shielding gas flow rates, wire feed rate, travel speed, current, and linear energy density. In the meantime, an additional trailing shielding mechanism was introduced to reduce surface oxidation while maintaining acceptable geometry for multiple-layer deposition. The multiple-layer deposited with optimized parameters shows complete fusion without visible voids. However, some interface separations were found due to the minor surface oxidation in between layers. Equiaxed-to-columnar grain structure was also observed along the deposition direction where molybdenum carbides were present. Further hardness test on the multiple-layer sample shows a superior isotropic hardness (HV 218) when compared with wrought Hastelloy X (HV 179). Multiple-layer depositing techniques were satisfactorily developed to prevent overheating.

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  • Copyright © 2022 the author(s). Theses may be used for non-commercial research, educational, or related academic purposes only. Such uses include personal study, research, scholarship, and teaching. Theses may only be shared by linking to Carleton University Institutional Repository and no part may be used without proper attribution to the author. No part may be used for commercial purposes directly or indirectly via a for-profit platform; no adaptation or derivative works are permitted without consent from the copyright owner.
Date Created
  • 2022


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