Wire Arc Additive Manufacturing of Ni-based Hastelloy C276 Alloy and Ameliorated Processes

Hastelloy C276 alloy, a typical Ni-based solid solution strengthened trademark superalloy, possesses excellent practical performance under severe environmental conditions and elevated temperatures. Hence, Hastelloy C276 has been investigated as a candidate for structural material for nuclear reactors, chemical processing and aerospace, particularly as aero-engine components. Wire arc additive manufacturing (WAAM), with its relatively high deposition efficiencies and cost-effectiveness, is revolutionising the 3D fabrication of advanced alloy components. However, the effectiveness of WAAM, for fabricating Ni-based alloys, is not fully understood. This thesis explores Hastelloy C276 structures deposited by the WAAM process, aiming to provide an insightful understanding of this process in the fabrication of Hastelloy C276 alloy and to assess and optimise different processing approaches, permitting a systematical investigation of process-microstructure-property interrelationships in WAAM fabricated Hastelloy C276.