Sensitivity of laser powder bed fusion additive manufactured HAYNES230 to composition and print parameters

Momeni, Kasra

doi:10.1016/j.jmrt.2021.11.080

Title: Sensitivity of laser powder bed fusion additive manufactured HAYNES230 to composition and print parameters

Journal Article · 24 November 2021 · Journal of Materials Research and Technology

DOI: https://doi.org/10.1016/j.jmrt.2021.11.080 · OSTI ID:1832509

^[1]

University of Alabama, Tuscaloosa, AL (United States)

We developed a coupled CALPHAD and finite element-based computational model of the Laser Powder Bed Fusion (LPBF) process for HAYNES230, considering the feedstock composition and packing density. We further used this model to investigate the effect of variation in feedstock composition and print parameters on the quality of the final printed part. Sensitivity of the maximum reached temperature to variations in characteristics of the laser source is also studied considering a single-track laser scan on a layer of metal powder. We analyzed temperature evolution in the powder bed and melt pool geometry along the path of the laser. Our results indicate that the LPBF process of HAYNES230 alloy requires a powder layer thickness of ~20 μm and laser spot size ~30 μm radius compared to other alloys. It is essential to achieve sufficient melt pool depth necessary for cohesion with the substrate while avoiding large melt pool width that adversely affects the formation of cracks and residual stresses. We also revealed that reducing the laser power or increasing scan speed drastically reduces peak temperature while less susceptible to solute composition.

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Research Organization:: Massachusetts Inst. of Technology (MIT), Cambridge, MA (United States)

Sponsoring Organization:: USDOE Advanced Research Projects Agency - Energy (ARPA-E)

Grant/Contract Number:: AR0001066

OSTI ID:: 1832509

Alternate ID(s):: OSTI ID: 1977346

Journal Information:: Journal of Materials Research and Technology, Vol. 15, Issue C; ISSN 2238-7854

Publisher:: Brazilian Metallurgical, Materials and Mining AssociationCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Materials Science
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HAYNES230 alloy
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