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Process development and application of hot forging arc-based additive manufacturing on Haynes® 282 for microstructural and mechanical improvements
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Resumo(s)
Haynes® 282, a nickel-based superalloy, is renowned for its exceptional strength, thermal stability, and resistance to oxidation and creep. While directed energy deposition arc-based additive manufacturing of this alloy has been explored, the formation of large columnar grains and high texture leading to anisotropy and suboptimal mechanical performance remains a significant challenge. This study introduces an interlayer in-situ mechanical deformation approach, known as hot forging, to address these issues. The hot forging process, applied at high temperatures, aims to refine grain structure, reduce porosity, and enhance mechanical properties. The dynamic analysis of the process using a high-speed camera imaging allowed to calculate a forging force exceeding 1000 N. Two single-bead multi-layered walls were fabricated, one with hot forging and one without. Results demonstrated a 22 % reduction in porosity upon hot forging. Electron backscatter diffraction analysis indicated that the hot forged sample has less texture, and the average grain size decreased from 1746 to 1262 μm and from 1053 to 696 μm in the top and middle wall regions, respectively. Synchrotron X-ray diffraction revealed a small variation in phase composition and confirmed that hot forging promotes refined grain structures with less texture. The ultimate tensile strength in the horizontal direction improved by 8 % with hot forging, while elongation decreased by 30 %. Electrical conductivity and microhardness measurements were similar for both processes. The findings confirm the efficacy of in-situ hot forging in enhancing microstructure and mechanical performance, highlighting its potential for high-cost and low-machinability materials in arc-based additive manufacturing.
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Funding Information:
The authors acknowledge Fundação para a Ciência e a Tecnologia (FCT, I.P.) for its financial support via the project UIDB/00667/2020 and UIDP/00667/2020 (UNIDEMI). JPO acknowledges funding by national funds from FCT - Fundaçao ˜ para a Ciˆencia e a Tecnologia, I.P., in the scope of the projects LA/P/0037/2020, UIDP/50025/2020 and UIDB/50025/2020 of the Associate Laboratory Institute of Nanostructures, Nanomodelling and Nanofabrication – i3N. IOF acknowledges Fundação para a Ciência e a Tecnologia (FCT, I.P.), Portugal, for funding the Ph.D. Grant 2023.03610.BD. JS acknowledges the China Scholarship Council for funding the Ph.D. grant (CSC NO. 201808320394). This activity has received funding from the European Institute of Innovation and Technology (EIT) – Project Smart WAAM: Microstructural Engineering and Integrated Non-Destructive Testing. This body of the European Union receives support from the European Union’s Horizon 2020 Research and Innovation Programme.
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© 2025 The Authors
Palavras-chave
Arc-based additive manufacturing Grain refinement Haynes® 282 Hot forging Mechanical strength Mechanics of Materials Mechanical Engineering Metals and Alloys Materials Chemistry