Hastelloy X Powder for Additive Manufacturing (3D Printing)
Hastelloy X powder is a nickel-based superalloy powder with exceptional high temperature strength and outstanding oxidation and corrosion resistance properties.
| Metal Powder | Size | Quantity | Price/kg |
| Hastelloy X | 15-45um | 1KG | 107 |
| 10KG | 79 | ||
| 100KG | 70 |
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Table of Contents
Hastelloy X Powder Overview
Hastelloy X powder is a nickel-based superalloy powder with exceptional high temperature strength and outstanding oxidation and corrosion resistance properties. It retains mechanical properties up to 1150°C making it suitable for critical components in aerospace engines, industrial gas turbines, chemical processing, and molten metal handling.
Hastelloy X powder can be used to fabricate parts from this high performance alloy via powder bed fusion additive manufacturing processes like laser powder bed fusion (LPBF) and electron beam powder bed fusion (EBM). This enables complex geometries to be printed directly from CAD data without the constraints of traditional casting and machining.
Compared to conventional nickel superalloys, Hastelloy X has superior creep rupture strength thanks to strategic additions of other elements like cobalt and molybdenum. It resists oxidizing, reducing and neutral atmospheres up to extreme temperatures prolonging component service life.
With additive manufacturing, designers can construct lighter Hastelloy X parts with conformal cooling channels and integrated assemblies not feasible previously. This guide covers Hastelloy X powder compositions, properties data, applications, printer parameters, and suppliers to leverage benefits of this alloy.
Composition of Hastelloy X Powder
Hastelloy X is a Ni-Cr-Fe-Co-Mo alloy with trace additions of other elements to enhance specific properties. The nominal composition by weight percent is:
| Element | Ni | Cr | Fe | Co | Mo | W | Mn | Si |
|---|---|---|---|---|---|---|---|---|
| Weight % | bal. | 21.5 | 18.5 | 12.5 | 9.0 | 0.6 | 0.5 | 0.5 |
- Nickel is the main base element providing a FCC crystal matrix. It lowers coefficient of thermal expansion.
- Chromium helps with oxidation and corrosion resistance through a protective chromium oxide layer forming on the surface.
- Iron, cobalt and molybdenum strengthen the material with solid solution mechanisms. Cobalt also maintains ductility.
- Tungsten further improves high temperature strength via carbide formation.
- Trace elements like manganese and silicon enhance castability and hot workability.
Modifications beyond this standard composition aim to tailor the alloy for specific requirements like higher strength or fabricability or to minimize certain elements.
Properties of Hastelloy X Powder
Hastelloy X possesses an excellent combination of high temperature strength, corrosion resistance, fabricability and weldability. Key attributes are:
| Property | Value |
|---|---|
| Density | 8.22 g/cm3 |
| Melting Point | 1350°C |
| Tensile Strength | 760 MPa (at 20°C)<br>140 MPa (at 1090°C) |
| Elongation % | 50% (at 20°C) |
| Thermal Conductivity | 11.3 W/m-K |
| Coefficient of Thermal Expansion | 13.0 μm/m-°C |
| Modulus of Elasticity | 196-214 GPa |
| Poisson’s Ratio | 0.29-0.32 |
- Retains 55% of room temperature strength up to 900°C. Creep rupture strength exceeds 100 MPa for over 1000 hours at 980°C.
- Resists hot corrosion and oxidation in high velocity gases up to extreme temperatures. Protective Cr2O3 oxide layer forms.
- Fabricability is good owing to 45-55% cold workability and high temperature hot workability. Machinability is rated 35% of 303 stainless steel.
- Exhibits excellent weldability. Low carbon content minimizes carbide precipitation during welding.
Printed Hastelloy X Properties
Mechanical properties of AM Hastelloy X parts depend on build orientation, processing parameters and heat treatments. Isotropic properties are attainable in the annealed state. Example data:
| Property | As-printed EBMF | As-printed LPBF |
|---|---|---|
| Tensile Strength | 330 – 470 MPa | 500 – 660 MPa |
| Yield Strength (0.2%) | 230 MPa | 320 MPa |
| Elongation at Break | 37% | 35% |
Applications of Hastelloy X
Hastelloy X sees heavy usage in:
Aerospace: Combustion chambers, spray bars, tubes, cases, fasteners, and housings in aircraft engines and land-based power generation turbines given its extreme temperature and environmental resistance.
Chemical Processing: Reformer tubes, cracking coils, heat exchangers, valve parts exposed to hydrocarbon processing and mixed industrial atmospheres at elevated temperatures seeking corrosion resistance.
Molten Metal Processing: Crucibles, thermocouple sheaths, fasteners, and pump/valve components contacting molten glass, aluminum, zinc, lead, copper, steel and superalloys during casting, coating and smelting operations.
Pollution Control: Ducting, stacks, scrubbers, fans, dampers handling hot acidic exhaust gases in waste incineration plants and coal-fired power stations which induce oxidation and corrosion.
Metalworking: Hot forming dies, extrusion containers and tooling holding superalloys, titanium and refractory metals at high temperatures during thermo-mechanical processing where heat and wear resistance is vital.
Hastelloy X Parts Made with Additive Manufacturing
Benefits of additively manufacturing components in Hastelloy X include:
- Fabricating intricate cooling channels and bionic geometries improving functionality
- Consolidating assemblies to reduce part count
- Customizing alloys to further enhance properties
- Accelerated design iteration and parts on demand
- Reduced lead times and inventories
- Construction of complex sandwich structures with lattices
- Lightweighting components through topology optimization
Process Parameters for Printing Hastelloy X Powder
LPBF and EBM involve spreading thin layers of metal powder ~20-100 microns thick and selectively melting areas based on 3D CAD data using a laser beam or electron beam respectively. Key parameters for Hastelloy X include:
LPBF Settings
| Parameter | Range |
|---|---|
| Laser power (W) | 195 – 380 W |
| Scan speed (mm/s) | 600-1550 mm/s |
| Beam size (μm) | 50-200 μm |
| Layer thickness (μm) | 20-50 μm |
| Hatch spacing (μm) | 80-140 μm |
| Shielding gas | Argon |
EBM Settings
| Parameter | Range |
|---|---|
| Beam power (W) | 2.0-3.5 kW |
| Beam speed (m/s) | 1000-3000 m/s |
| Beam size (μm) | 200 |
| Layer thickness (μm) | 50-200 μm |
| Line offset (μm) | 100 |
| Preheat temp (°C) | 1000°C |
Part density above 99% is achieved in both processes after stress relieving and hot isostatic pressing. Minimum feature sizes of ~100-200 microns are possible.
Suppliers of Hastelloy X Powder for AM
| Company | Product Designation | Particle Size |
|---|---|---|
| Met3DP | Hastelloy X Powder | 15-45 μm |
| Carpenter Additive | Hastelloy X MicroMelt Spherical Powder | 10-45 μm |
| AP&C | Hastelloy X45 AM Powder | D10 45 μm |
| America Makes | Hastelloy X Gas Atomized Powder | D50 17 μm |
| Metal Powders | Custom Hastelloy X Alloys | 10-53 μm |
| Atlantic Equipment | Hastelloy X 3D Printing Powder | 22-71 μm |
Cost of Hastelloy X Powder
As a niche superalloy powder for high performance applications, Hastelloy X powder prices are higher:
- Metal powder material cost is $500-$1000 per kg
- Lead times for custom orders may range from 2 to 16 weeks
Met3DP Hastelloy X powder price list:
| Metal Powder | Size | Quantity | Price/kg |
| Hastelloy X | 15-45um | 1KG | 107 |
| 10KG | 79 | ||
| 100KG | 70 |
Mechanical Testing Standards
Key test methods used to evaluate the tensile, fatigue, fracture toughness and creep rupture properties of Hastelloy X material and powders include:
| Standard | Title | Organization |
|---|---|---|
| ASTM E8 | Tension Testing of Metallic Materials | ASTM |
| ASTM E23 | Notched Bar Impact Testing | ASTM |
| ISO 6892 | Metallic Materials Tensile Testing | ISO |
| AMS 2633A | Heat Treatment of Hastelloy X Parts | SAE |
Post Processing of Additively Manufactured Hastelloy X Parts
After printing, Hastelloy X parts must undergo the following post processing steps before putting into service:
Support Removal
- Sacrificial supports are detached using wire EDM cutting or chemical dissolution where accessible.
Stress Relieving
- To eliminate residual stresses from the layerwise buildup, heat gently under vacuum or inert gas to 760-980°C for 1-2 hours.
Hot Isostatic Pressing
- HIP the entire print at 1120°C temperature and 100-200 MPa pressure for 3-6 hours to close internal voids and microporosity.
Heat Treatment
- Solution annealing between 1150-1210°C ensures equilibrium microstructure and desired hardness.
Surface Processing
- Additional surface treatments involve grinding, milling, polishing and shot peening to attain required surface roughness and finish.
Quality Testing
- Test parts meet specifications for dimensions, material integrity, microstructure and mechanical properties per applicable standards. Conduct layerwise scanning.
Buyer’s Guide – Hastelloy X Powder Bed 3D Printers
Critical printer considerations for working with reactive alloys like Hastelloy X powder include:
Precision – tight process controls for dimensional accuracy and repeatability over builds
Inert Atmosphere – very high purity shielding gas to prevent material contamination
Automation – powder handling systems to minimize oxygen exposure
Quality Assurance – inline monitoring, closed loop feedback of melt pools and microstructure
Smart Software – special scanning strategies adapting to thermal history and geometry
Productivity – faster build rates through higher laser power and large build volumes
Leading models include:
- 3D Systems DMP Factory 500
- GE Additive Concept Laser Xline 2000R
- EOS M 400-4 4-laser system
- SLM Solutions Next Generation series
- Renishaw RenAM 500 Quad laser machine
Future Outlook for Hastelloy X and Metal AM
The applications for Hastelloy X components will expand within existing sectors as additive techniques enable newer possibilities combined with increasing economic viability:
- More common use directly 3D printing rocket combustion chambers, commercial jet engine parts, industrial gas turbine hot sections and power generation hardware given enhanced geometric, cooling and weight benefits.
- Additional chemical equipment like heat exchanger internals and process tanks with conformal channels printed as one body rather than welded sheet metal assemblies.
- Consolidating module assemblies and traditionally brazed joints for aerospace and semiconductor production equipment susceptible to vacuum and high purity corrosive atmospheres.
- Customized, unitized fuel injector assemblies and effusion cooling plates tailored to specific thermal environments in liquid propulsion systems and turbines.
- Increased adoption of patient matched implants like dental bridges and crowns taking advantage of biocompatibility.
The future of metal AM itself is very positive due to greater affordability along with faster build rates and turnaround times. Manufacturing applications of the technology keep expanding.
FAQs
Q: What is Hastelloy X most known for regarding its alloy properties?
A: Hastelloy X is most renowned for retaining high strength at extreme temperatures up to 1150°C along with superb corrosion resistance allowing it to endure hot oxidizing and reducing atmospheres in demanding environments.
Q: What industries use Hastelloy X and its related superalloys the most?
A: Aerospace is the leading consumer of Hastelloy X exploiting its heat resistance – over 50% usage. Next is chemical processing relying on corrosion resistance, followed by metal processing and pollution control applications.
Q: What makes Hastelloy X better than other Ni-based superalloys for extreme environments?
A: Strategic additions of iron, cobalt and molybdenum give Hastelloy X the highest strength among nickel alloys up to 1150°C. Other Ni superalloys either fall short of this max temperature or eventually get outperformed in rupture strength duration.
Q: What is the typical cost per kg of Hastelloy X powder suitable for AM powder bed processes?
A: Because Hastelloy X is a specialty powder tailored to demanding applications, its pricing ranges from $500 to $1000 per kg normally. This is 5-10X stainless steel costs for example. There is further markup for lower quantity orders.
Q: Which 3D printing process works better for Hastelloy X – DMLS or EBM?
A: Both LPBF and EBM can print fully dense Hastelloy X components. Laser based processes may offer better surface finish and dimensional precision down to ~50 microns detail. But EBM’s faster build rate makes it preferred for higher volume production applications.
Q: What heat treatment is used for Hastelloy X parts after metal AM construction?
A: The typical heat treatment cycle involves 1-2 hours of soaking between 1150°C to 1210°C after a 1080°C stress relief first. This homogenizes elements in the matrix providing desired phase balance and properties.
Q: Is Hastelloy X harder or easier to machine than standard 304 or 316 stainless steel grades?
A: Hastelloy X has nearly 50% lower machinability rating relative to common 300 series stainless steels because of its higher strength and work hardening characteristics. More rigid setups and appropriate tooling required.
Q: Can you weld Hastelloy X superalloy using conventional fusion welding methods?
A: Yes, Hastelloy X shows excellent weldability via gas tungsten arc welding (GTAW), plasma or laser beam techniques owing to low carbon and absence of strengthening precipitates along grain boundaries that can form brittle intermetallic phases. Use matching filler alloy.
Q: What industries will drive future adoption of metal AM using alloys like Hastelloy X?
A: Aerospace, medical, automotive and energy industries have some of the highest value applications for printed metal parts made from alloys which balance properties like temperature resistance, corrosion resistance and high strength where lightweight constructions confer significant benefits.
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