AccScience Publishing / MSAM / Volume 4 / Issue 1 / DOI: 10.36922/msam.8069
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ORIGINAL RESEARCH ARTICLE

Evaluation of microstructure, tensile, and fatigue testing on angled walls of NASA HR-1 using laser powder direct energy deposition

Javier Lares1,2* ,  Edel Arrieta2,3 ,  Lawrence E. Murr1 ,  Colton Katsarelis4 ,  Paul Gradl4 ,  Francisco Medina2,3
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1 Department of Metallurgical, Materials and Biomedical Engineering, College of Engineering, The University of Texas at El Paso, El Paso, Texas, United States of America
2 W.M. Keck Center for 3D Innovation, College of Engineering, The University of Texas at El Paso, El Paso, Texas, United States of America
3 Department of Mechanical Engineering, College of Engineering, The University of Texas at El Paso, El Paso, Texas, United States of America
4 National Aeronautics and Space Administration, Marshall Space Flight Center, Huntsville, Alabama, United States of America
MSAM 2025, 4(1), 8069 https://doi.org/10.36922/msam.8069
Submitted: 19 December 2024 | Accepted: 3 February 2025 | Published: 26 March 2025
© 2025 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

This study investigates the influence of varying deposition angles on the tensile strength and low cycle fatigue (LCF) performance of National Aeronautics and Space Administration (NASA) HR-1 alloy using laser powder-directed energy deposition. This study investigates the influence of varying deposition angles on the tensile strength and LCF performance of NASA HR-1 alloy using laser powder-directed energy deposition. Two sets of build parameters, 1,070 W and 2,620 W, were employed alongside three different build angles to assess their influence on mechanical properties following a uniform heat treatment regimen. This heat treatment encompassed stress relief, homogenization, solution annealing, and double aging. Samples deposited at 1,070 W showed a slightly lower porosity percentage compared to those produced at 2,620 W. All samples displayed similar grain sizes and a homogenized microstructure, indicating the effectiveness of the heat treatment in achieving a uniform microstructure across samples deposited at different build angles and laser power settings. The varying deposition angles did not significantly affect the microstructure or mechanical properties of the alloy. Fractography analysis revealed that all samples fractured through transgranular micro-void coalescence, with fracture initiation predominately occurring at the edges of both tensile and fatigue samples.

Keywords
NASA HR-1 alloy
Laser power direct energy deposition
Build angle
Laser power
Funding
Primary funding was provided by grant number 80NSSC23PC201 from the NASA Marshall Space Flight.
Conflict of interest
The authors declare that they have no financial or personal conflicts of interest that could have appeared to influence the work reported in this paper.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing
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