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<p>Surface roughness is essential for the performance of components additively manufactured. Reducing it during the powder bed fusion process can also be a cost-effective approach. Hastelloy X was chosen due to its excellent oxidation resistance and application in hot combustion sections of gas turbines. In this study, the surface roughness was decreased using the border scanning strategy. To determine the appropriate range of parameters for the border strategy, the effects of laser power and scanning speed on the geometry of single-track lines, including height, width, penetration depth, and wetting angle of the weld bead, as well as balling occurrence, were investigated in the first step. Based on the results obtained in this step, the penetration depth and width increase, whereas the wetting angle and balling occurrence decrease with increasing laser power and decreasing scanning speed. The 350 and 450&#xa0;W laser powers were selected for the border evaluations. In the second step, the effects of border offset and laser power on the surface roughness of Hastelloy X samples manufactured by powder bed fusion were investigated. By increasing the border offset up to 0.02&#xa0;mm, the average roughness of samples on the side surface, made using 450 and 350&#xa0;W laser powers, decreases from 28.3 to 19.7&#xa0;µm and from 24.7 to 12.5&#xa0;µm, respectively.</p>

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Effect of Border Offset and Laser Power on Surface Roughness in Powder Bed Fusion of Hastelloy X Alloy

  • 期刊论文

  • 发表日期：

    2026年2月11日

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  • M. Amiri,
  • A. Farzadi,
  • M. Khajehzadeh,
  • A. Fathi

摘要

Surface roughness is essential for the performance of components additively manufactured. Reducing it during the powder bed fusion process can also be a cost-effective approach. Hastelloy X was chosen due to its excellent oxidation resistance and application in hot combustion sections of gas turbines. In this study, the surface roughness was decreased using the border scanning strategy. To determine the appropriate range of parameters for the border strategy, the effects of laser power and scanning speed on the geometry of single-track lines, including height, width, penetration depth, and wetting angle of the weld bead, as well as balling occurrence, were investigated in the first step. Based on the results obtained in this step, the penetration depth and width increase, whereas the wetting angle and balling occurrence decrease with increasing laser power and decreasing scanning speed. The 350 and 450 W laser powers were selected for the border evaluations. In the second step, the effects of border offset and laser power on the surface roughness of Hastelloy X samples manufactured by powder bed fusion were investigated. By increasing the border offset up to 0.02 mm, the average roughness of samples on the side surface, made using 450 and 350 W laser powers, decreases from 28.3 to 19.7 µm and from 24.7 to 12.5 µm, respectively.