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Title: Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

Abstract

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

Authors:
 [1];  [1];  [2];  [1];  [1];  [1];  [1];  [2];  [2]
+ Show Author Affiliations
  1. Sandia National Lab. (SNL-CA), Livermore, CA (United States)
  2. Univ. of California, Irvine, CA (United States)
Publication Date:
Research Org.:
Sandia National Lab. (SNL-CA), Livermore, CA (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1357021
Report Number(s):
SAND-2017-4008
Journal ID: ISSN 1059-9630; PII: 480
Grant/Contract Number:  
AC04-94AL85000
Resource Type:
Accepted Manuscript
Journal Name:
Journal of Thermal Spray Technology
Additional Journal Information:
Journal Volume: 26; Journal Issue: 4; Journal ID: ISSN 1059-9630
Publisher:
Springer
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 42 ENGINEERING; additive manufacturing; dendritic; LENS; porosity; stainless steel

Citation Formats

Yang, Nancy, Yee, J., Zheng, B., Gaiser, K., Reynolds, T., Clemon, L., Lu, W. Y., Schoenung, J. M., and Lavernia, E. J. Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering. United States: N. p., 2016. Web. doi:10.1007/s11666-016-0480-y.
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Yang, Nancy, Yee, J., Zheng, B., Gaiser, K., Reynolds, T., Clemon, L., Lu, W. Y., Schoenung, J. M., & Lavernia, E. J. Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering. United States. https://doi.org/10.1007/s11666-016-0480-y
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Yang, Nancy, Yee, J., Zheng, B., Gaiser, K., Reynolds, T., Clemon, L., Lu, W. Y., Schoenung, J. M., and Lavernia, E. J. Thu . "Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering". United States. https://doi.org/10.1007/s11666-016-0480-y. https://www.osti.gov/servlets/purl/1357021.
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@article{osti_1357021,
title = {Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering},
author = {Yang, Nancy and Yee, J. and Zheng, B. and Gaiser, K. and Reynolds, T. and Clemon, L. and Lu, W. Y. and Schoenung, J. M. and Lavernia, E. J.},
abstractNote = {We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.},
doi = {10.1007/s11666-016-0480-y},
journal = {Journal of Thermal Spray Technology},
number = 4,
volume = 26,
place = {United States},
year = {Thu Dec 08 00:00:00 EST 2016},
month = {Thu Dec 08 00:00:00 EST 2016}
}
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Publisher's Version of Record
https://doi.org/10.1007/s11666-016-0480-y
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Works referenced in this record:

Understanding thermal behavior in the LENS process
journal, June 1999

Residual stresses and microstructure of H13 steel formed by combining two different direct fabrication methods
journal, October 1998

Laser additive manufacturing of metallic components: materials, processes and mechanisms
journal, May 2012

Thermal Behavior and Microstructure Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part II. Experimental Investigation and Discussion
journal, June 2008

  • Zheng, B.; Zhou, Y.; Smugeresky, J. E.
  • Metallurgical and Materials Transactions A, Vol. 39, Issue 9
  • DOI: 10.1007/s11661-008-9566-6

Thermal Behavior and Microstructural Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part I. Numerical Calculations
journal, June 2008

  • Zheng, B.; Zhou, Y.; Smugeresky, J. E.
  • Metallurgical and Materials Transactions A, Vol. 39, Issue 9
  • DOI: 10.1007/s11661-008-9557-7

Solidification in direct metal deposition by LENS processing
journal, September 2001

A survey of sensing and control systems for machine and process monitoring of directed-energy, metal-based additive manufacturing
journal, March 2015

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    A Comparative Study of the Efficacy of Local/Global and Parametric/Nonparametric Machine Learning Methods for Establishing Structure–Property Linkages in High-Contrast 3D Elastic Composites
    journal, March 2019

    • Fernandez-Zelaia, Patxi; Yabansu, Yuksel C.; Kalidindi, Surya R.
    • Integrating Materials and Manufacturing Innovation, Vol. 8, Issue 2
    • DOI: 10.1007/s40192-019-00129-4

    Advances in additive manufacturing of metal-based functionally graded materials
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