Abstract: Laser additive manufacturing technology provides a new technological approach for the design and manufacturing of high-performance metal components in the internal flow channel of complex tail nozzles in the aerospace field. The complex and variable channel diameters and forming angles of internal channel components pose a serious challenge to the integrated forming of laser additive manufacturing. Using Hastelloy X (HX) powder as the raw material, a nickel based high-temperature alloy circular inner channel component is formed using laser powder bed fusion (LPBF) technology. The effects of channel diameter and forming angle on the forming quality of the inner channel are studied, and an optimized plan for LPBF forming of nickel based high-temperature composite inner channel components is provided. Research has shown that when the diameter of the flow channel increases and the forming angle approaches 90 °, the deviation in the contour size of the inner flow channel is relatively small, only 3.35%. When the diameter of the flow channel increases from 0.5 mm to 2.0 mm, the actual deviation value in the X direction of the inner flow channel decreases from 22% to 6.25%; The actual deviation value in the Y direction has decreased from 16% to 4.75%; When the forming angle is close to the vertical plane, the forming density of the component is increased (98.8%). When the forming angle increases from 0 ° to 90 °, the density of the inner channel increases from 96% to 98.8%, and the surface roughness Ra decreases from 73.46 μm to 16.11 μm.

Key words: laser powder bed fusion, internal channel, Hastelloy X, channel diameter, forming angle