Nickel Alloy HX Powder

Qualification and Printing

Qualifying new materials like Nickel Alloy HX powder for additive manufacturing involves extensive characterization and process development:

Nickel Alloy HX Powder Qualification

• Chemical analysis – Confirm composition conformity to specification via wet chemistry or OES
• Particle size distribution – Validate powder sphericity and size parameters using laser diffraction
• Apparent density and flow measurements – Check suitability for powder spreading using Hall flowmeter as per ASTM B213 standard
• Internal porosity assessment – Analyze density uniformity and internal defects using microCT scans
• Microstructure characterization – Use SEM and EDS to evaluate alloy uniformity, precipitation and defects
• Process parameter development – Optimize laser power, speed, hatch spacing for density >99.5% using test cubes
• Mechanical testing – Perform tensile, fatigue, fracture toughness, creep on AM test parts and compare to wrought properties
• Non-destructive evaluation – Use techniques like dye-penetrant testing to identify surface/sub-surface defects
• Corrosion testing – Evaluate corrosion rate in relevant environments through immersion testing or ASTM standards
• Post-processing – Study effect of hot isostatic pressing (HIP) and heat treatment on properties
• Application demonstration – Fabricate real component prototypes and measure functional performance against design targets

This extensive testing validates the alloy powder quality and its suitability for printing application components meeting the required property targets.

Print Parameter Guidelines

Typical parameters for printing Nickel Alloy HX powder on SLM 125HL system from SLM Solutions:

Parameters vary based on factors like desired properties, surface finish, build rate priorities and AM system capabilities. Parameter sets get continually refined through rigorous DOE approaches to expand printable geometry and property range.

Post-Processing

Common post-processing steps for additively manufactured Nickel Alloy HX components include:

• Removal from build plate – Wire EDM or band saw cutting to remove parts from plate
• Support removal – Carefully remove auto-generated supports mechanically or using EDM
• Stress relief – Heat component uniformly to 620°C for 1-2 hours to relieve residual stresses
• Hot isostatic pressing – HIP at 1160°C/100-200 MPa for 4 hours to eliminate internal porosity >98% density
• Surface treatment – Abrasive flow machining and media blasting enhances surface finish
• Dimension measurement – Confirm critical dimensions using CMM inspection and scan for geometric accuracy
• Dye-penetrant testing – Check for surface breaking flaws needing repair using fluorescent or visible dye penetrants
• Heat treatment – Solution treat 1120°C, rapid air cool + age 720°C/16 hrs for desired properties

Automating post-processing operations is crucial considering geometric complexity of additively manufactured components using Nickel Alloy HX powder.

Careful design and support strategies are also vital during pre-processing to improve downstream efficiency. Periodic inspection should validate all design and certification requirements are being met.

Applications and Case Studies

Nickel Alloy HX is being applied across demanding application areas:

Aerospace

• Combustor cans – 40% weight reduction, handles 100°C higher temperatures
• Commercial jet bleed valve housing – Integrated cooling channels, optimized fluid flow
• Satellite thruster chambers – High strength-to-weight ratio, reusable

Oil and Gas

• Sour gas valve bodies – Corrosion resistant nickel alloy withstands H2S environment
• Downhole safety valve components – Withstands 150°C temperatures and erosion
• Offshore pump impeller – Lightweight, efficient fluid handing under seawater

Automotive

• Turbocharger compressor wheel – High speed capability to 110,000 rpm
• Exhaust control valve – Handles exhaust gas temperatures up to 1050°C
• Piston crown – Conformal cooling channels enable higher power density engine

Industrial

• Continuous casting nozzle – High temperature fluid flow device boosts steel plant productivity
• Extrusion press tooling – Improved durability and double the life
• Printing press heating element – Integrated nickel alloy circuit handles 700°C temperatures

These application examples showcase the potential of Nickel Alloy HX to push performance boundaries across industries through additive techniques. More widespread availability of parameter data and demonstrations will further expand adoption.

FAQs

Q: What are the main advantages Nickel Alloy HX offers over conventional materials?

Nickel Alloy HX provides an exceptional combination of high strength up to 1095°C along with toughness and corrosion resistance not achievable with typical alloys. Additive manufacturability enables designs not possible with subtractive techniques.

Q: What heat treatment is used for Nickel Alloy HX AM parts?

Solution treatment at 1120°C followed by aging at 720°C for 16 hrs enables an excellent balance of strength (>150 ksi UTS) and ductility (>16% El.). HIP is applied post-build and prior to heat treatment.

Q: What AM process is ideal for nickel alloy HX powder?

Selective laser melting (SLM) is preferred over Electron Beam Melting for Nickel Alloy HX to better control thermal stresses and cracking. SLM allows higher density while controlling directional properties.

Q: What industries offer the best opportunities for Nickel Alloy HX AM adoption?

Aerospace, oil and gas, automotive and industrial heat treatment industries are adopting nickel alloy HX for components demanding thermal stability, strength and corrosion performance.

Q: Does Nickel Alloy HX require any special powder handling or storage precautions?

Nickel alloy powders are not hazardous though respiratory and explosion precautions are prudent as with any fine metal powder. Argon inert storage with moisture controls preserves long term reusability.