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<p>Challenges such as build chamber size limitations, residual stress generation, and anisotropic properties associated with laser powder bed fusion (LPBF) in the fabrication of large structures can be mitigated using hybrid designs that integrate additively manufactured components with conventionally manufactured parts. The feasibility of such hybrid components will be proven through weldability. This study investigates microstructural changes occurring in keyhole TIG-welded samples of LPBF-manufactured and wrought Haynes 282 plates and the influence of welding on the mechanical properties of the resultant joint. The hybrid weldment exhibited higher tensile strength compared to the weldment made with wrought plates on both sides, and this finding was further supported by fatigue testing of the welded samples. The drop in the hardness of HAZ on the printed side is less compared to the wrought-aged side. The combination of thermal cycling effects and strain-induced dislocations results in a higher hardness profile seen in the HAZ of the printed side (HAZ-P) compared to the HAZ of the wrought side (HAZ-W). This study confirms that welding additively manufactured Haynes 282 with wrought Haynes 282 is a workable option for joining additively manufactured heat exchanger components of complex geometry.</p>

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Joining of Laser Powder Bed Fusion-Manufactured and Wrought Components of Haynes 282 Alloy

  • 期刊论文

  • 发表日期：

    2025年10月29日

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  • K. K. Jibi,
  • Abhishek Shukla,
  • M. Arunkumar,
  • Gandham Phanikumar

摘要

Challenges such as build chamber size limitations, residual stress generation, and anisotropic properties associated with laser powder bed fusion (LPBF) in the fabrication of large structures can be mitigated using hybrid designs that integrate additively manufactured components with conventionally manufactured parts. The feasibility of such hybrid components will be proven through weldability. This study investigates microstructural changes occurring in keyhole TIG-welded samples of LPBF-manufactured and wrought Haynes 282 plates and the influence of welding on the mechanical properties of the resultant joint. The hybrid weldment exhibited higher tensile strength compared to the weldment made with wrought plates on both sides, and this finding was further supported by fatigue testing of the welded samples. The drop in the hardness of HAZ on the printed side is less compared to the wrought-aged side. The combination of thermal cycling effects and strain-induced dislocations results in a higher hardness profile seen in the HAZ of the printed side (HAZ-P) compared to the HAZ of the wrought side (HAZ-W). This study confirms that welding additively manufactured Haynes 282 with wrought Haynes 282 is a workable option for joining additively manufactured heat exchanger components of complex geometry.