Page 89 - MSAM-4-1

Materials Science in

Additive Manufacturing

ORIGINAL RESEARCH ARTICLE
Evaluation of microstructure, tensile, and fatigue

testing on angled walls of NASA HR-1 using laser
powder direct energy deposition

Javier Lares 1,2† * , Edel Arrieta 2,3 , Lawrence E. Murr 1 , Colton Katsarelis 4† ,
Paul Gradl 4† , and Francisco Medina 2,3
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

Abstract

† These authors contributed equally
to this work This study investigates the influence of varying deposition angles on the tensile
strength and low cycle fatigue (LCF) performance of National Aeronautics and Space
*Corresponding author:
Javier Lares Administration (NASA) HR-1 alloy using laser powder-directed energy deposition.
(jelaresmona@miners.utep.edu) 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
Citation: Lares J, Arrieta E,
Murr LE, Katsarelis C, energy deposition. Two sets of build parameters, 1,070 W and 2,620 W, were employed
Gradl P, Medina F. Evaluation of alongside three different build angles to assess their influence on mechanical
microstructure, tensile, and fatigue properties following a uniform heat treatment regimen. This heat treatment
testing on angled walls of NASA
HR-1 using laser powder direct encompassed stress relief, homogenization, solution annealing, and double
energy deposition. Mater Sci Add aging. Samples deposited at 1,070 W showed a slightly lower porosity percentage
Manuf. 2025;4(1):8069. compared to those produced at 2,620 W. All samples displayed similar grain sizes and
doi: 10.36922/msam.8069
a homogenized microstructure, indicating the effectiveness of the heat treatment
Received: December 19, 2024 in achieving a uniform microstructure across samples deposited at different build
1st revised: January 14, 2025 angles and laser power settings. The varying deposition angles did not significantly
affect the microstructure or mechanical properties of the alloy. Fractography analysis
2nd revised: January 30, 2025
revealed that all samples fractured through transgranular micro-void coalescence,
Accepted: February 3, 2025 with fracture initiation predominately occurring at the edges of both tensile and
Published Online: March 26, 2025 fatigue samples.
Copyright: © 2025 Author(s).
This is an Open-Access article Keywords: NASA HR-1 alloy; Laser power direct energy deposition; Build angle; Laser
distributed under the terms of the
Creative Commons Attribution power
License, permitting distribution,
and reproduction in any medium,
provided the original work is
properly cited. 1. Introduction
Publisher’s Note: AccScience
Publishing remains neutral with National Aeronautics and Space Administration (NASA) HR-1, developed by the
regard to jurisdictional claims in
published maps and institutional NASA, is an iron-nickel-chromium-based superalloy used in high-pressure hydrogen
affiliations. applications. It is an iron-nickel-based gamma prime-strengthened superalloy derived

Volume 4 Issue 1 (2025) 1 doi: 10.36922/msam.8069