Hostname: page-component-586b7cd67f-dsjbd Total loading time: 0 Render date: 2024-11-28T06:22:52.271Z Has data issue: false hasContentIssue false
  • English
  • Français

Effect of metallurgical defect and phase transition on geometric accuracy and wear resistance of iron-based parts fabricated by selective laser melting

Published online by Cambridge University Press:  19 April 2016

Hongyu Chen  and
Dongdong Gu
Hongyu Chen
Affiliation:
College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, Jiangsu Province, People's Republic of China; and Institute of Additive Manufacturing (3D Printing), Nanjing University of Aeronautics and Astronautics, Nanjing 210016, Jiangsu Province, People's Republic of China
Dongdong Gu*
Affiliation:
College of Materials Science and Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, Jiangsu Province, People's Republic of China; and Institute of Additive Manufacturing (3D Printing), Nanjing University of Aeronautics and Astronautics, Nanjing 210016, Jiangsu Province, People's Republic of China
*
a)Address all correspondence to this author. e-mail: [email protected]
Get access

Abstract

A systematic analysis of effect of metallurgical defect and phase transition on geometric accuracy and wear resistance of iron-based parts fabricated by selective laser melting was conducted. By composition optimization of alloying elements, the desirable martensitic structure was directly obtained based on high-speed laser induction and the content of retained austenite was observed to be different under various laser parameters. Using an optimized scan speed of 1600 mm/s could lead to the highest densification level of 99.24% and the lowest content of retained austenite of 3.5%, hence acquiring a considerably high Rockwell hardness of 61.9 HRC, a reduced coefficient of friction of 0.40, and wear rate of 1.8 × 10−5 mm3/N m. A thorough investigation of dimension offset due to martensite transformation in conjunction with theoretical calculation was performed. Lower top surface roughness (5.25 μm) and reduced side roughness (13.84 μm) were achieved at the optimized scan speed of 1600 mm/s.

Keywords

selective laser meltingphase transitionaccuracyroughnesswear property
Type
Articles
Information
Journal of Materials Research , Volume 31 , Issue 10 , 28 May 2016 , pp. 1477 - 1490
Copyright
Copyright © Materials Research Society 2016 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

REFERENCES

Attar, H., Bonisch, M., Calin, M., Zhang, L.C., Zhuravleva, K., Funk, A., Scudino, S., Yang, C., and Eckert, J.: Comparative study of microstructures and mechanical properties of in situ Ti–TiB composites produced by selective laser melting, powder metallurgy, and casting technologies. J. Mater. Res. 29, 1941 (2014).Google Scholar
Sun, S.B., Zheng, L.J., Liu, Y.Y., Liu, J.H., and Zhang, H.: Characterization of Al–Fe–V–Si heat-resistant aluminum alloy components fabricated by selective laser melting. J. Mater. Res. 30, 1661 (2015).Google Scholar
Zhang, B.C., Fenineche, N.-E., Liao, H.L., and Coddet, C.: Microstructure and Magnetic properties of Fe–Ni alloy fabricated by selective laser melting Fe/Ni mixed powders. J. Mater. Sci. Technol. 29, 757 (2013).Google Scholar
Ma, C.L., Gu, D.D., Dai, D.H., Chen, W.H., Chang, F., Yuan, P.P., and Shen, Y.F.: Aluminum-based nanocomposites with hybrid reinforcements prepared by mechanical alloying and selective laser melting consolidation. J. Mater. Res. 30, 2816 (2015).Google Scholar
Simchi, A., Petzoldt, F., and Pohl, H.: On the development of direct metal laser sintering for rapid tooling. J. Mater. Process. Technol. 141, 319 (2003).CrossRefGoogle Scholar
Thijs, L., Verhaeghe, F., Craeghs, T., Van Humbeeck, J., and Kruth, J.P., A study of the microstructural evolution during selective laser melting of Ti–6Al–4V. Acta Mater. 58, 3303 (2010).CrossRefGoogle Scholar
Simonelli, M., Tse, Y.Y., and Tuck, C.: The formation of alpha plus beta microstructure in as-fabricated selective laser melting of Ti–6Al–4V. J. Mater. Res. 29, 2028 (2014).CrossRefGoogle Scholar
Wen, S.F., Li, S., Wei, Q.S., Chunze, Y., Zhang, S., and Shi, Y.S.: Effect of molten pool boundaries on the mechanical properties of selective laser melting parts. J. Mater. Process. Technol. 214, 2660 (2014).Google Scholar
Liu, Z.H., Zhang, D.Q., Chua, C.K., and Leong, K.F., Crystal structure analysis of M2 high speed steel parts produced by selective laser melting. Mater. Charact. 84, 72 (2013).Google Scholar
Holzweissig, M.J., Taube, A., Brenne, F., Schaper, M., and Niendorf, T.: Microstructural characterization and mechanical performance of hot work tool steel processed by selective laser melting. Metall. Mater. Trans. B-Proc. Metall. Mater. Proc. Sci. 46, 545 (2015).Google Scholar
Jagle, E.A., Choi, P.P., Van Humbeeck, J., and Raabe, D.: Precipitation and austenite reversion behavior of a maraging steel produced by selective laser melting. J. Mater. Res. 29, 2072 (2014).Google Scholar
Liu, Y.J., Li, X.P., Zhang, L.C., and Sercombe, T.B.: Processing and properties of topologically optimised biomedical Ti–24Nb–4Zr–8Sn scaffolds manufactured by selective laser melting. Mater. Sci. Eng., A 642, 268 (2015).CrossRefGoogle Scholar
Gu, D.D., Hagedorn, Y.-C., Meiners, W., Meng, G.B., Batista, R.J.S., Wissenbach, K., and Poprawe, R.: Densification behavior, microstructure evolution, and wear performance of selective laser melting processed commercially pure titanium. Acta Mater. 60, 3849 (2012).CrossRefGoogle Scholar
Zhu, H.H., Lu, L., and Fuh, J.Y.H.: Influence of binder's liquid volume fraction on direct laser sintering of metallic powder. Mater. Sci. Eng., A 371, 170 (2004).Google Scholar
Gu, D.D., Hagedorn, Y.-C., Meiners, W., Wissenbach, K., and Poprawe, R.: Nanocrystalline TiC reinforced Ti matrix bulk-form nanocomposites by selective laser melting (SLM): Densification, growth mechanism and wear behavior. Compos. Sci. Technol. 71, 1612 (2011).Google Scholar
Simchi, A.: Direct laser sintering of metal powders: Mechanism, kinetics and microstructural features. Mater. Sci. Eng. A 428, 148 (2006).Google Scholar
Arafune, K. and Hirata, A.: Thermal and solutal Marangoni convection in In–Ga–Sb system. J. Cryst. Growth 197, 811 (1999).Google Scholar
Simchi, A. and Pohl, H.: Effects of laser sintering processing parameters on the microstructure and densification of iron powder. Mater. Sci. Eng. A 359, 119 (2003).Google Scholar
Louvis, E., Fox, P., and Sutcliffe, C.J.: Selective laser melting of aluminium components. J. Mater. Process. Technol. 211, 275 (2011).CrossRefGoogle Scholar
Atwood, R.C., Sridhar, S., Zhang, W., and Lee, P.D.: Diffusion-controlled growth of hydrogen pores in aluminium-silicon castings: On situ observation and modeling. Acta Mater. 48, 405 (2000).CrossRefGoogle Scholar
Weingarten, C., Buchbinder, D., Pirch, N., Meiners, W., Wissenbach, K., and Poprawe, R.: Formation and reduction of hydrogen porosity during selective laser melting of AlSi10Mg. J. Mater. Process. Technol. 221, 112 (2015).Google Scholar
Li, R.D., Liu, J.H., Shi, Y.S., Wang, L., and Jiang, W.: Balling behavior of stainless steel and nickel powder during selective laser melting process. Int. J. Adv. Manuf. Technol. 59, 1025 (2012).CrossRefGoogle Scholar
Yin, H. and Felicelli, S.D.: Dendrite growth simulation during solidification in the LENS process. Acta Mater. 58, 1455 (2010).Google Scholar
Liu, C., Wang, D.Z., Liu, Y.X., Zhu, Q.H., and Zhao, Y.: Composition design of a new type low-alloy high-strength steel. Mater. Des. 18, 53 (1997).Google Scholar
Zhou, Y. and Wu, G.H.: Analysis Methods in Materials Science—x-ray Diffraction and Electron Microscopy in Materials Science, 2nd ed. (Harbin Institute of Technology Press, Harbin, China, 2007).Google Scholar
Song, B., Dong, S.J., Deng, S.H., Liao, H.L., and Coddet, C.: Microstructure and tensile properties of iron parts fabricated by selective laser melting. Opt. Laser Technol. 56, 451 (2014).Google Scholar
Liu, Y.C., Lan, F., Yang, G.C., and Zhou, Y.H.: Microstructural evolution of rapidly solidified Ti-Al peritectic alloy. J. Cryst. Growth 271, 313 (2004).Google Scholar
Schwarz, M., Arnold, C.B., Aziz, M.J., and Herlach, D.M.: Dendritic growth velocity and diffusive speed in solidification of undercooled dilute Ni-Zr melts. Mater. Sci. Eng. A 226–228, 420 (1997).CrossRefGoogle Scholar
Zhang, S.H., Wang, P., Li, D.Z., and Li, Y.Y.: Investigation of the evolution of retained austenite in Fe–13%Cr–4%Ni martensitic stainless steel during intercritical tempering. Mater. Des. 84, 385 (2015).Google Scholar
Ma, M.M., Wang, Z.M., Gao, M., and Zeng, X.Y.: Layer thickness dependence of performance in high-power selective laser melting of 1Cr18Ni9Ti stainless steel. J. Mater. Process. Technol. 215, 142 (2015).Google Scholar
Wang, D., Yang, Y.Q., Su, X.B., and Chen, Y.H.: Study on energy input and its influences on single-track, multi-track, and multi-layer in SLM. Int. J. Adv. Manuf. Technol. 58, 1189 (2012).Google Scholar
Santos, E.C., Shiomi, M., Osakada, K., and Laoui, T.: Rapid manufacturing of metal components by laser forming. Int. J. Mach. Tools Manuf. 46, 1459 (2006).Google Scholar
Alrbaey, K., Wimpenny, D., Tosi, R., Manning, W., and Moroz, A.: On optimization of surface roughness of selective laser melted stainless steel parts: A Statistical study. J. Mater. Eng. Perform. 23, 2139 (2014).Google Scholar
Wang, D., Yang, Y.Q., Yi, Z.H., and Su, X.B.: Research on the fabricating quality optimization of the overhanging surface in SLM process. Int. J. Adv. Manuf. Technol. 65, 1471 (2013).Google Scholar
Mumtaz, K. and Hopkinson, N.: Top surface and side roughness of Inconel 625 parts processed using selective laser melting. Rapid Prototyping J. 15, 96 (2009).Google Scholar
Gu, D.D. and Shen, Y.F.: Balling phenomena during direct laser sintering of multi-component Cu-based metal powder. J. Alloy. Compd. 432, 163 (2007).Google Scholar
Murali, K., Chatterjee, A.N., Saha, P., Palai, R., Kumar, S., Roy, S.K., Mishra, P.K., and Roy Choudhury, A.: Direct selective laser sintering of iron-graphite powder mixture. J. Mater. Process. Technol. 136, 179 (2003).Google Scholar
Sun, Y., Moroz, A., and Alrbaey, K.: Sliding wear characteristics and corrosion behaviour of selective laser melted 316L stainless steel. J. Mater. Eng. Perform. 23, 518 (2014).Google Scholar