Origin of dislocation structures in an additively manufactured austenitic stainless steel 316L

Bertsch, K. M.; Meric de Bellefon, G.; Kuehl, B.; Thoma, D. J.

doi:10.1016/j.actamat.2020.07.063

Origin of dislocation structures in an additively manufactured austenitic stainless steel 316L

Journal Article · Fri Aug 14 00:00:00 EDT 2020 · Acta Materialia

DOI:https://doi.org/10.1016/j.actamat.2020.07.063· OSTI ID:1690234

Bertsch, K. M. ^[1]; Meric de Bellefon, G. ^[2]; Kuehl, B. ^[2]; Thoma, D. J. ^[2]

Univ. of Wisconsin, Madison, WI (United States); Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Lawrence Livermore National Laboratory, Livermore, CA 94550, USA
Univ. of Wisconsin, Madison, WI (United States)

In this experiment, the origin of dislocation structures in AM stainless steels was systematically investigated by controlling the effect of thermal stress through geometric constraints for the first time. Stainless steel 316L parts were produced in the form of “1D” rods, “2D” walls, and "3D" rectangular prisms to evaluate the effect of constraints to thermal expansion/shrinkage on the development of defect microstructures and to elucidate the origin of additively manufactured (AM) dislocation microstructures. Dislocation density, organization, chemical micro-segregation, precipitate structures, and misorientations were analyzed as a function of increasing constraints around solidifying material in 1D, 2D, and 3D components built using both directed energy deposition (DED) and powder-bed selective laser melting (SLM). In DED parts, the dislocation density was not dependent on local misorientations or micro-segregation patterns, but evolved from approximately ρ_⊥ = 10¹² m^-2 in 1D parts to ρ_⊥ = 10¹⁴ m^-2 in 3D parts, indicating that it is primarily thermal distortions that produce AM dislocation structures. In DED 3D parts and SLM parts, dislocation densities were highest (ρ_⊥ ≈ 10¹⁴ m^-2) and corresponded to the formation of dislocation cells approximately 300-450 nm in diameter. Dislocation cells overlapped with dendrite micro-segregation in some but not all cases. The results illustrate that dendritic micro-segregation, precipitates, or local misorientations influence how the dislocations organize during processing, but are not responsible for producing the organized cell structures. Furthermore, this work shows that AM dislocation structures originate due to thermal distortions during printing, which are primarily dictated by constraints surrounding the melt pool and thermal cycling.

View Accepted Manuscript (DOE)

Research Organization:: Georgia Institute of Technology, Atlanta, GA (United States)

Sponsoring Organization:: NSF-DMREF; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344; NA0003921

OSTI ID:: 1690234

Alternate ID(s):: OSTI ID: 1648371

Journal Information:: Acta Materialia, Journal Name: Acta Materialia Vol. 199; ISSN 1359-6454

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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