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Effect of direct energy deposition parameters on morphology, residual stresses, density, and microstructure of 1.2709 maraging steel

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Abstract

In this study, one-dimensional beads and three-dimensional cubes of 1.2709 maraging steel were printed using a laser additive manufacturing (AM) technology. The direct energy deposition (DED) was firstly employed to evaluate the optimal conditions of the single-bead deposition. High-energy (> 64.9 J/mm2) and low-energy (< 64.9 J/mm2) groups of beads were deposited according to a full factorial design of experiment (DOE) and analyzed regarding the optimal aspect ratio between 3 and 5. The low-energy DED was evaluated as the optimal one regarding the required morphology with large process window. The effect of DED process parameters on density/porosity, microstructure, and residual stresses of the cubic specimens was then analyzed. It was found that by reducing the laser energy and print overlap, it is possible to drastically reduce the residual stresses as well as by increasing the powder density. Scanning strategies do not have a strong influence on residual stresses but affect the porosity. Moreover, the porosity is increased with increasing laser energy and print overlap. The best compromise between porosity, residual stresses, and productivity was obtained with a surface energy of 35 J/mm2, a 30% overlap, and a bidirectional-rotation scanning strategy. The presented work highlights the essential experimental data for an upcoming DED of large parts and their characterization suitable for industrial injection molding applications.

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The authors confirm that the data supporting the findings of this study are openly available and transparent.

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Acknowledgements

The authors would like to thank the Auvergne-Rhone-Alpes Region for their funding and the PCI company for technical and financial support.

Funding

This work has been financed by the Auvergne-Rhône-Alpes Region.

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Authors and Affiliations

  1. University of Lyon, Ecole Centrale de Lyon - ENISE, LTDS CNRS UMR 5513, 58 rue Jean Parot, 42023, Saint-Etienne, France

    Kulish Aleksandr, Salvatore Ferdinando & Rech Joel

  2. PCI SCEMM, Campus Industriel, Rue de Copernic, 42100, Saint-Étienne, France

    Courbon Joel

  3. INSA Lyon, 20 Avenue Albert Einstein, 69100, Villeurbanne, France

    Munoz Jordan

  4. CT-IPC, 2 rue Pierre & Marie Curie, 01100, Bellignat, France

    Joffre Thomas

Authors
  1. Kulish Aleksandr
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  2. Salvatore Ferdinando
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  3. Rech Joel
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  4. Courbon Joel
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  5. Munoz Jordan
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  6. Joffre Thomas
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Contributions

Aleksandr K. and Jordan M. carried out the experiments. Aleksandr K. carried out the result analysis and wrote the manuscript with support from Joel R., Ferdinando S., Joel C., and Thomas J. All authors provided critical feedback and helped shape the research and analysis.

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Correspondence to Kulish Aleksandr.

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Aleksandr, K., Ferdinando, S., Joel, R. et al. Effect of direct energy deposition parameters on morphology, residual stresses, density, and microstructure of 1.2709 maraging steel. Int J Adv Manuf Technol 117, 1287–1301 (2021). https://doi.org/10.1007/s00170-021-07635-w

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