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Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Effect of Microstructural and Geometrical Features on Low Cycle Fatigue Properties of Additively Manufactured Hastelloy X
Author(s) Ajay Kushwaha, Ritam Pal, Brandon Kemerling, Daniel Ryan, Sudhakar Bollapragada, Amrita Basak
On-Site Speaker (Planned) Ajay Kushwaha
Abstract Scope Nickel-based superalloys such as Hastelloy X are widely used for high-temperature turbine components. While laser powder bed fusion (LPBF) enables fabrication of complex geometries, it introduces structural vulnerabilities like anisotropic microstructures and stochastic defects. This research investigates how macroscopic geometric features and microscopic heterogeneities influence the low cycle fatigue (LCF) behavior of LPBF Hastelloy X. Using an integrated approach, notched LCF tests quantified life reduction from stress concentrators, while Bayesian-calibrated crystal plasticity (CP) simulations isolated microstructural influences in un-notched machined specimens. Results show that notched failure is dominated by multi-site initiation at surface-connected lack of fusion defects. Additionally, surface roughness varies within the geometry depending on local build angle. CP simulations revealed plastic strain localization within coarse grains and near twin boundaries. These results provide a baseline for identifying geometric and microstructural fatigue drivers and support future investigations of surface-microstructure interactions in LPBF Hastelloy X.
Proceedings Inclusion? Undecided

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