Tempering kinetics during multilayer laser additive manufacturing of a ferritic steel

Mukherjee, Tuhin; DebRoy, Tarasankar; Lienert, Thomas J.; Maloy, Stuart A.; Lear, Calvin Robert; Hosemann, Peter

doi:10.1016/j.jmapro.2022.08.061

Tempering kinetics during multilayer laser additive manufacturing of a ferritic steel

Journal Article · Tue Sep 06 00:00:00 EDT 2022 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2022.08.061· OSTI ID:1908661

Mukherjee, Tuhin ^[1]; DebRoy, Tarasankar ^[1]; Lienert, Thomas J. ^[2]; Maloy, Stuart A. ^[3]; ^[4]; ^[5]

Pennsylvania State Univ., University Park, PA (United States)
Optomec, Inc., Albuquerque, NM (United States)
Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)
Univ. of California, Berkeley, CA (United States)

Grade 91 steel forms martensite during additive manufacturing and the extent of tempering of martensite significantly affects the mechanical properties of parts. Currently, there is a lack of quantitative understanding of the tempering kinetics for Grade 91 steel, and as a result, the effects of repeated thermal cycles on properties for different processing conditions cannot be determined. Here we evaluate the tempering kinetics by determining the constant terms in the Johnson Mehl Avrami kinetic equation from the tempering data available in the literature and the thermal cycles computed using a rigorously-tested heat and fluid flow model of multi-layer additive manufacturing. The raw tempering data are cleaned using a neural network to enhance accuracy. The lower layers experience repeating cycles of heating and cooling when the upper layers are added. As a result, the hardness is reduced owing to the tempering of martensite. In contrast, martensite formed in the upper layers is not tempered to the same extent and the hardness remains high. Therefore, the hardness of the part increases with the distance from the substrate. Variations in the heat input at different laser powers and scanning speeds significantly affect the extent of tempering. Finally, since the method used here can provide a quantitative understanding of the tempering of martensite and the spatial variation in hardness, it can be used to tailor the microstructure and hardness of heat treatable printed metallic parts.

View Accepted Manuscript (DOE)

Research Organization:: Los Alamos National Laboratory (LANL), Los Alamos, NM (United States); Pacific Northwest National Laboratory (PNNL), Richland, WA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Nuclear Energy (NE)

Grant/Contract Number:: 89233218CNA000001; AC05-76RL01830

OSTI ID:: 1908661

Alternate ID(s):: OSTI ID: 1886724
OSTI ID: 3009676

Report Number(s):: LA-UR--24-24071; PNNL-SA--177178

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Vol. 83; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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