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Microstructural Development and Technical Challenges in Laser Additive Manufacturing: Case Study with a 316L Industrial Part

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Abstract

Additive manufacturing (AM) brings disruptive changes to the ways parts, and products are designed, fabricated, tested, qualified, inspected, marketed, and sold. These changes introduce novel technical challenges and concerns arising from the maturity and diversity of today’s AM processes, feedstock materials, and process parameter interactions. AM bears a resemblance with laser and electron beam welding in the so-called conduction mode, which involves a multitude of dynamic physical events between the projected feedstock and a moving heat source that eventually influence AM part properties. For this paper, an air vent was selected for its thin-walled, hollow, and variable cross section, and limited size. The studied air vents, randomly selected from a qualification batch, were fabricated out of 316L stainless steel using a 4 kW fiber laser powder-fed AM system, referred to as construction laser additive direct (CLAD). These were systematically characterized by microhardness indentation, visual examination, optical and scanning electron microscopy, and electron-back-scattering diffraction in order to determine AM part suitability for service and also broadly discuss metallurgical phenomena. The paper then briefly expands the discussion to include additional engineering alloys and further analyze relationships between AM process parameters and AM part properties, consistently utilizing past experience with the same powder-fed CLAD 3D printer, the well-established science and technology of welding and joining, and recent publications on additive manufacturing.

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Authors and Affiliations

  1. Materials Engineering Department, Enabling Technology Group, Schlumberger Technology Corporation, Rosharon Center, 14910 Airlines Road, Rosharon, TX, 77583, USA

    Manuel Marya (Materials Engineering Manager) & Virendra Singh (Materials Engineering)

  2. Institut de Recherches en Génie Civil et Mécanique, Ecole Centrale Nantes, 1 Rue de la Noë, 44300, Nantes Cedex, France

    Surendar Marya (Emeritus Professor)

  3. Institut de Recherches en Communications et Cybernétiques de Nantes, Ecole Centrale Nantes, 1 Rue de la Noë, 44300, Nantes Cedex, France

    Jean Yves Hascoet (Professor & Dean Research)

Authors
  1. Manuel Marya
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  2. Virendra Singh
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  3. Surendar Marya
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  4. Jean Yves Hascoet
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Correspondence to Jean Yves Hascoet.

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Manuscript submitted August 29, 2014.

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Marya, M., Singh, V., Marya, S. et al. Microstructural Development and Technical Challenges in Laser Additive Manufacturing: Case Study with a 316L Industrial Part. Metall Mater Trans B 46, 1654–1665 (2015). https://doi.org/10.1007/s11663-015-0310-5

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  • DOI: https://doi.org/10.1007/s11663-015-0310-5

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