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

M. D. Barath Kumar | Zendy; R. Madesh | Zendy; M. Sathishkumar | Zendy; D. Sakthimurugan | Zendy; Keerthipalli Trinath | Zendy; S. Sathiyamurthy | Zendy; V. Praveen Kumar | Zendy; M. Vignesh | Zendy

Open Access

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

Author(s) -

M. D. Barath Kumar,

R. Madesh,

M. Sathishkumar,

D. Sakthimurugan,

Keerthipalli Trinath,

S. Sathiyamurthy,

V. Praveen Kumar,

M. Vignesh

Publication year - 2025

Publication title -

ieee access

Language(s) - English

Resource type - Magazines

SCImago Journal Rank - 0.587

H-Index - 127

eISSN - 2169-3536

DOI - 10.1109/access.2025.3598731

Subject(s) - aerospace , bioengineering , communication, networking and broadcast technologies , components, circuits, devices and systems , computing and processing , engineered materials, dielectrics and plasmas , engineering profession , fields, waves and electromagnetics , general topics for engineers , geoscience , nuclear engineering , photonics and electrooptics , power, energy and industry applications , robotics and control systems , signal processing and analysis , transportation

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 μm, 78.6 μm, and 87.6 μm while C-276 has 72.5 μm, 80.2 μm, and 96.8 μm, 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 ±5.1MPa, whereas Hastelloy C-276 displayed a tensile strength of 758±4.1MPa 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-basedWAAM technologies is limited and progressing. The comparative results of this research will be significant in the chemical-based, nuclear energy, maritime, and manufacturing industries.

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