Formation of functionally graded steel by laser powder bed fusion via in-situ carbon doping

Sperry, McKay G.; Nelson, Tracy W.; Crane, Nathan B.

doi:10.1016/j.jmapro.2024.11.015

Formation of functionally graded steel by laser powder bed fusion via in-situ carbon doping

Journal Article · Tue Nov 19 23:00:00 EST 2024 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2024.11.015· OSTI ID:2538569

Sperry, McKay G. ^[1]; Nelson, Tracy W. ^[2]; Crane, Nathan B. ^[2]

Brigham Young University, Provo, UT (United States); Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Brigham Young University, Provo, UT (United States)

Additive Manufacturing (AM) enables functional integration by combining multiple components into a single part to shorten assembly time, reduce weight, and improve performance. Laser Powder Bed Fusion (LPBF) is an important AM method due to excellent spatial resolution, surface finish, and material properties without the need for extensive post-processing. Functional integration could be enhanced by spatial tuning of properties, but LPBF cannot readily vary material composition. Here, this paper addresses a method to add spatial composition control by printing small quantities of dopants via liquid carrier prior to laser fusion. The impact of carbon black suspension added to select regions of a Stainless Steel 316 L powder bed on melt pool dimension, hardness, and porosity is reported. The distribution of the carbon between the doped and plain layers and the resulting spatial variation in hardness is measured. Optical microscopy and composition analysis show that the carbon dispersed uniformly within the layer of deposition and diffused as little as 50 μm in the build direction. Keyhole conditions dramatically increase the inter-layer transport of the dopant. The added carbon increased hardness by >50 %. Porosity increased in doped regions but remained below 1.5 % for the best processing parameters. These results demonstrate that the composition of LPBF parts could be controlled in 3-dimensions using a dopant that is soluble in the melt pool. Additional work will be required to evaluate different dopant materials and optimize processing conditions for full density, but microalloying with soluble dopants appears to be a plausible solution to enhance functional integration with LPBF.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; USNRC

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 2538569

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Vol. 132; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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