Crack mitigation in Laser Powder Bed Fusion processed Hastelloy X using a combined numerical-experimental approach

•Crack-free Hastelloy X parts were produced with reduced hatch spacing and top-hat laser.•Experimental and numerical studies were compared for a Gaussian and top-hat laser.•The effect of laser beam profile, hatch spacing and cooling rate was investigated.•Reducing the hatch spacing decreases the cooling rate and creates a pre-heated zone.•Crack-free Hastelloy X parts result in combined high strength and elongation.