Evolution of 316L stainless steel feedstock due to laser powder bed fusion process
Abstract
Some of the primary barriers to widespread adoption of metal additive manufacturing (AM) are persistent defect formation in built components, high material costs, and lack of consistency in powder feedstock. To generate more reliable, complex-shaped metal parts, it is crucial to understand how feedstock properties change with reuse and how that affects build mechanical performance. Powder particles interacting with the energy source, yet not consolidated into an AM part can undergo a range of dynamic thermal interactions, resulting in variable particle behavior if reused. Here in this work, we present a systematic study of 316L powder properties from the virgin state through thirty powder reuses in the laser powder bed fusion process. Thirteen powder characteristics and the resulting AM build mechanical properties were investigated for both powder states. Results show greater variability in part ductility for the virgin state. The feedstock exhibited minor changes to size distribution, bulk composition, and hardness with reuse, but significant changes to particle morphology, microstructure, magnetic properties, surface composition, and oxide thickness. Additionally, sieved powder, along with resulting fume/condensate and recoil ejecta (spatter) properties were characterized. Formation mechanisms are proposed. It was discovered that spatter leads to formation of single crystal ferrite through large degreesmore »
- Authors:
-
- Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
- Publication Date:
- Research Org.:
- Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
- Sponsoring Org.:
- USDOE National Nuclear Security Administration (NNSA)
- OSTI Identifier:
- 1485816
- Report Number(s):
- SAND-2018-13210J
Journal ID: ISSN 2214-8604; 670222
- Grant/Contract Number:
- AC04-94AL85000
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Additive Manufacturing
- Additional Journal Information:
- Journal Volume: 25; Journal Issue: C; Journal ID: ISSN 2214-8604
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE
Citation Formats
Heiden, Michael J., Deibler, Lisa A., Rodelas, Jeff M., Koepke, Josh R., Tung, Dan J., Saiz, David J., and Jared, Bradley H. Evolution of 316L stainless steel feedstock due to laser powder bed fusion process. United States: N. p., 2019.
Web. doi:10.1016/j.addma.2018.10.019.
Heiden, Michael J., Deibler, Lisa A., Rodelas, Jeff M., Koepke, Josh R., Tung, Dan J., Saiz, David J., & Jared, Bradley H. Evolution of 316L stainless steel feedstock due to laser powder bed fusion process. United States. https://doi.org/10.1016/j.addma.2018.10.019
Heiden, Michael J., Deibler, Lisa A., Rodelas, Jeff M., Koepke, Josh R., Tung, Dan J., Saiz, David J., and Jared, Bradley H. Tue .
"Evolution of 316L stainless steel feedstock due to laser powder bed fusion process". United States. https://doi.org/10.1016/j.addma.2018.10.019. https://www.osti.gov/servlets/purl/1485816.
@article{osti_1485816,
title = {Evolution of 316L stainless steel feedstock due to laser powder bed fusion process},
author = {Heiden, Michael J. and Deibler, Lisa A. and Rodelas, Jeff M. and Koepke, Josh R. and Tung, Dan J. and Saiz, David J. and Jared, Bradley H.},
abstractNote = {Some of the primary barriers to widespread adoption of metal additive manufacturing (AM) are persistent defect formation in built components, high material costs, and lack of consistency in powder feedstock. To generate more reliable, complex-shaped metal parts, it is crucial to understand how feedstock properties change with reuse and how that affects build mechanical performance. Powder particles interacting with the energy source, yet not consolidated into an AM part can undergo a range of dynamic thermal interactions, resulting in variable particle behavior if reused. Here in this work, we present a systematic study of 316L powder properties from the virgin state through thirty powder reuses in the laser powder bed fusion process. Thirteen powder characteristics and the resulting AM build mechanical properties were investigated for both powder states. Results show greater variability in part ductility for the virgin state. The feedstock exhibited minor changes to size distribution, bulk composition, and hardness with reuse, but significant changes to particle morphology, microstructure, magnetic properties, surface composition, and oxide thickness. Additionally, sieved powder, along with resulting fume/condensate and recoil ejecta (spatter) properties were characterized. Formation mechanisms are proposed. It was discovered that spatter leads to formation of single crystal ferrite through large degrees of supercooling and massive solidification. Finally, ferrite content and consequently magnetic susceptibility of the powder also increases with reuse, suggesting potential for magnetic separation as a refining technique for altered feedstock.},
doi = {10.1016/j.addma.2018.10.019},
journal = {Additive Manufacturing},
number = C,
volume = 25,
place = {United States},
year = {Tue Jan 01 00:00:00 EST 2019},
month = {Tue Jan 01 00:00:00 EST 2019}
}
Web of Science
Works referenced in this record:
Laser and electron-beam powder-bed additive manufacturing of metallic implants: A review on processes, materials and designs: LASER AND ELECTRON-BEAM ADDITIVE MANUFACTURING OF METALLIC IMPLANTS
journal, October 2015
- Sing, Swee Leong; An, Jia; Yeong, Wai Yee
- Journal of Orthopaedic Research, Vol. 34, Issue 3
Design for Additive Manufacturing: Trends, opportunities, considerations, and constraints
journal, January 2016
- Thompson, Mary Kathryn; Moroni, Giovanni; Vaneker, Tom
- CIRP Annals, Vol. 65, Issue 2
Comparative study of commercially pure titanium produced by laser engineered net shaping, selective laser melting and casting processes
journal, September 2017
- Attar, Hooyar; Ehtemam-Haghighi, Shima; Kent, Damon
- Materials Science and Engineering: A, Vol. 705
Selective Laser Melting (SLM) of pure gold
journal, June 2010
- Khan, Mushtaq; Dickens, Phill
- Gold Bulletin, Vol. 43, Issue 2
In-process sensing in selective laser melting (SLM) additive manufacturing
journal, February 2016
- Spears, Thomas G.; Gold, Scott A.
- Integrating Materials and Manufacturing Innovation, Vol. 5, Issue 1
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
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
Material issues in additive manufacturing: A review
journal, January 2017
- Singh, Sunpreet; Ramakrishna, Seeram; Singh, Rupinder
- Journal of Manufacturing Processes, Vol. 25
Formation and reduction of hydrogen porosity during selective laser melting of AlSi10Mg
journal, July 2015
- Weingarten, Christian; Buchbinder, Damien; Pirch, Norbert
- Journal of Materials Processing Technology, Vol. 221
The role of particle size on the laser sintering of iron powder
journal, October 2004
- Simchi, A.
- Metallurgical and Materials Transactions B, Vol. 35, Issue 5
Materials for additive manufacturing
journal, January 2017
- Bourell, David; Kruth, Jean Pierre; Leu, Ming
- CIRP Annals, Vol. 66, Issue 2
The Application of Powder Rheology in Additive Manufacturing
journal, January 2015
- Clayton, Jamie; Millington-Smith, Doug; Armstrong, Brian
- JOM, Vol. 67, Issue 3
Optimising metal powders for additive manufacturing
journal, September 2014
- Clayton, Jamie
- Metal Powder Report, Vol. 69, Issue 5
Additive manufacturing of metals
journal, September 2016
- Herzog, Dirk; Seyda, Vanessa; Wycisk, Eric
- Acta Materialia, Vol. 117
Relationship between powder characteristics and part properties in laser beam melting of Ti–6Al–4V, and implications on quality
journal, May 2017
- Seyda, Vanessa; Herzog, Dirk; Emmelmann, Claus
- Journal of Laser Applications, Vol. 29, Issue 2
Effect of IN718 Recycled Powder Reuse on Properties of Parts Manufactured by Means of Selective Laser Melting
journal, January 2014
- Ardila, L. C.; Garciandia, F.; González-Díaz, J. B.
- Physics Procedia, Vol. 56
Recyclability Study on Inconel 718 and Ti-6Al-4V Powders for Use in Electron Beam Melting
journal, October 2015
- Nandwana, Peeyush; Peter, William H.; Dehoff, Ryan R.
- Metallurgical and Materials Transactions B, Vol. 47, Issue 1
Characterization and Control of Powder Properties for Additive Manufacturing
journal, January 2015
- Strondl, A.; Lyckfeldt, O.; Brodin, H.
- JOM, Vol. 67, Issue 3
Effect of Powder Reuse Times on Additive Manufacturing of Ti-6Al-4V by Selective Electron Beam Melting
journal, February 2015
- Tang, H. P.; Qian, M.; Liu, N.
- JOM, Vol. 67, Issue 3
On microstructure and mechanical properties of additively manufactured AlSi10Mg_200C using recycled powder
journal, November 2017
- Asgari, Hamed; Baxter, Carter; Hosseinkhani, Keyvan
- Materials Science and Engineering: A, Vol. 707
Investigation into spatter behavior during selective laser melting of AISI 316L stainless steel powder
journal, December 2015
- Liu, Yang; Yang, Yongqiang; Mai, Shuzhen
- Materials & Design, Vol. 87
Application of physical and chemical characterization techniques to metallic powders
conference, January 2014
- Slotwinski, J. A.; Watson, S. S.; Stutzman, P. E.
- 40TH ANNUAL REVIEW OF PROGRESS IN QUANTITATIVE NONDESTRUCTIVE EVALUATION: Incorporating the 10th International Conference on Barkhausen Noise and Micromagnetic Testing, AIP Conference Proceedings
Characterization of Metal Powders Used for Additive Manufacturing
journal, January 2014
- Slotwinski, J. A.; Garboczi, E. J.; Stutzman, P. E.
- Journal of Research of the National Institute of Standards and Technology, Vol. 119
Liquid metal expulsion during laser spot welding of 304 stainless steel
journal, January 2006
- He, X.; Norris, J. T.; Fuerschbach, P. W.
- Journal of Physics D: Applied Physics, Vol. 39, Issue 3
Computer Vision and Machine Learning for Autonomous Characterization of AM Powder Feedstocks
journal, December 2016
- DeCost, Brian L.; Jain, Harshvardhan; Rollett, Anthony D.
- JOM, Vol. 69, Issue 3
Characterizing powder materials using keypoint-based computer vision methods
journal, January 2017
- DeCost, Brian L.; Holm, Elizabeth A.
- Computational Materials Science, Vol. 126
Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones
journal, April 2016
- Khairallah, Saad A.; Anderson, Andrew T.; Rubenchik, Alexander
- Acta Materialia, Vol. 108
In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing
journal, December 2017
- Scipioni Bertoli, Umberto; Guss, Gabe; Wu, Sheldon
- Materials & Design, Vol. 135
Analysis of laser–melt pool–powder bed interaction during the selective laser melting of a stainless steel
journal, May 2017
- Gunenthiram, Valérie; Peyre, Patrice; Schneider, Matthieu
- Journal of Laser Applications, Vol. 29, Issue 2
Denudation of metal powder layers in laser powder bed fusion processes
journal, August 2016
- Matthews, Manyalibo J.; Guss, Gabe; Khairallah, Saad A.
- Acta Materialia, Vol. 114
Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
journal, June 2017
- Ly, Sonny; Rubenchik, Alexander M.; Khairallah, Saad A.
- Scientific Reports, Vol. 7, Issue 1
Influence of particle properties on powder bulk behaviour and processability
journal, February 2017
- Shah, Umang V.; Karde, Vikram; Ghoroi, Chinmay
- International Journal of Pharmaceutics, Vol. 518, Issue 1-2
Introduction to the Additive Manufacturing Powder Metallurgy Supply Chain
journal, July 2015
- Dawes, Jason; Bowerman, Robert; Trepleton, Ross
- Johnson Matthey Technology Review, Vol. 59, Issue 3
Powder characterisation techniques and effects of powder characteristics on part properties in powder-bed fusion processes
journal, December 2016
- Sutton, Austin T.; Kriewall, Caitlin S.; Leu, Ming C.
- Virtual and Physical Prototyping, Vol. 12, Issue 1
New parameter of roundness R: circularity corrected by aspect ratio
journal, January 2016
- Takashimizu, Yasuhiro; Iiyoshi, Maiko
- Progress in Earth and Planetary Science, Vol. 3, Issue 1
High-throughput stochastic tensile performance of additively manufactured stainless steel
journal, March 2017
- Salzbrenner, Bradley C.; Rodelas, Jeffrey M.; Madison, Jonathan D.
- Journal of Materials Processing Technology, Vol. 241
Considerations for the weldability of types 304L and 316L stainless steel
journal, August 2001
- Korinko, P. S.; Malene, S. H.
- Practical Failure Analysis, Vol. 1, Issue 4
Improved weldability diagram for pulsed laser welded austenitic stainless steels
journal, February 2003
- Lienert, T. J.; Lippold, J. C.
- Science and Technology of Welding and Joining, Vol. 8, Issue 1
Impact of Defects in Powder Feedstock Materials on Microstructure of 304L and 316L Stainless Steel Produced by Additive Manufacturing
journal, May 2018
- Morrow, Benjamin M.; Lienert, Thomas J.; Knapp, Cameron M.
- Metallurgical and Materials Transactions A, Vol. 49, Issue 8
Manipulation and Characterization of a Novel Titanium Powder Precursor for Additive Manufacturing Applications
journal, February 2015
- Sun, Y. Y.; Gulizia, S.; Oh, C. H.
- JOM, Vol. 67, Issue 3
As-Fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting
journal, May 2011
- Vilaro, T.; Colin, C.; Bartout, J. D.
- Metallurgical and Materials Transactions A, Vol. 42, Issue 10
Effect of particle properties on the flowability of ibuprofen powders
journal, October 2008
- Liu, L. X.; Marziano, I.; Bentham, A. C.
- International Journal of Pharmaceutics, Vol. 362, Issue 1-2
Particle-based simulation of powder application in additive manufacturing
journal, January 2016
- Parteli, Eric J. R.; Pöschel, Thorsten
- Powder Technology, Vol. 288
The influence of grain shape, friction and cohesion on granular compaction dynamics
journal, March 2007
- Vandewalle, N.; Lumay, G.; Gerasimov, O.
- The European Physical Journal E, Vol. 22, Issue 3
Surface alloy depletion and martensite formation during glass to metal joining of austenitic stainless steels
journal, May 2012
- Susan, D. F.; Knorovsky, G. A.; Robino, C. V.
- Science and Technology of Welding and Joining, Vol. 17, Issue 4
Densification behavior of gas and water atomized 316L stainless steel powder during selective laser melting
journal, April 2010
- Li, Ruidi; Shi, Yusheng; Wang, Zhigang
- Applied Surface Science, Vol. 256, Issue 13
Powder bed charging during electron-beam additive manufacturing
journal, February 2017
- Cordero, Zachary C.; Meyer, Harry M.; Nandwana, Peeyush
- Acta Materialia, Vol. 124
Interparticle van der Waals force in powder flowability and compactibility
journal, August 2004
- Li, Qin; Rudolph, Victor; Weigl, Bernhard
- International Journal of Pharmaceutics, Vol. 280, Issue 1-2
The effect of recycling on the oxygen distribution in Ti-6Al-4V powder for additive manufacturing
journal, October 2017
- Sun, Yu; Aindow, Mark; Hebert, Rainer J.
- Materials at High Temperatures, Vol. 35, Issue 1-3
Calculation of self-diffusion coefficients in iron
journal, January 2014
- Zhang, Baohua
- AIP Advances, Vol. 4, Issue 1
Feedstock powder processing research needs for additive manufacturing development
journal, February 2018
- Anderson, Iver E.; White, Emma M. H.; Dehoff, Ryan
- Current Opinion in Solid State and Materials Science, Vol. 22, Issue 1
Quantitative characterization of porosity in stainless steel LENS powders and deposits
journal, July 2006
- Susan, D. F.; Puskar, J. D.; Brooks, J. A.
- Materials Characterization, Vol. 57, Issue 1
The microstructure and phase relationships in rapidly solidified type 304 stainless steel powders
journal, October 1988
- Wright, Richard N.; Flinn, John E.; Korth, Gary E.
- Metallurgical Transactions A, Vol. 19, Issue 10
Rapid solidification of a droplet-processed stainless steel
journal, May 1984
- Kelly, Thomas F.; Cohen, Morris; Sande, John B.
- Metallurgical Transactions A, Vol. 15, Issue 5
Delta Ferrite Formation in Austenitic Stainless Steel Castings
journal, November 2012
- Padilha, Angelo Fernando; Tavares, Caio Fazzioli; Martorano, Marcelo Aquino
- Materials Science Forum, Vol. 730-732
Solidification Structure of Gas-Atomized High-Speed Steel Powders
journal, January 1982
- Fischmeister, H. F.; Ozerskii, A. D.; Olsson, L.
- Powder Metallurgy, Vol. 25, Issue 1
Mechanisms and characteristics of spatter generation in SLM processing and its effect on the properties
journal, March 2017
- Wang, Di; Wu, Shibiao; Fu, Fan
- Materials & Design, Vol. 117
The Role of Microstructure and Surface Finish on the Corrosion of Selective Laser Melted 304L
journal, January 2018
- Schaller, Rebecca F.; Mishra, Ajit; Rodelas, Jeffrey M.
- Journal of The Electrochemical Society, Vol. 165, Issue 5
Works referencing / citing this record:
3D Shape Analysis of Powder for Laser Beam Melting by Synchrotron X-ray CT
journal, February 2019
- Thiede, Tobias; Mishurova, Tatiana; Evsevleev, Sergei
- Quantum Beam Science, Vol. 3, Issue 1
Defect Prevention in Selective Laser Melting Components: Compositional and Process Effects
journal, November 2019
- Sabzi, Hossein Eskandari; Rivera-Díaz-del-Castillo, Pedro E. J.
- Materials, Vol. 12, Issue 22