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Surface Residual Stress and Roughness Mapping for Different Build Locations in Laser Powder Bed Fusion of Maraging Steel

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Abstract

Metal laser powder bed fusion (L-PBF) technologies are being massively studied to achieve a broader implementation of their advantages over subtractive techniques. L-PBF benefits the development of components with high-performance and lightweight structures because of the layerwise approach, providing disruptive manufacturing. One main challenge in L-PBF is producing parts with controllable residual stresses naturally generated during materials processing. The complex thermal cycle experienced by the material during L-PBF manufacturing makes managing and controlling this feature even more challenging. This study investigated the effect of different build locations on the surface residual stress and roughness of maraging steel samples manufactured by L-PBF. X-ray diffraction (XRD) for residual stress assessment and area roughness (Sa) measurements using a confocal laser scanning microscopy (CLSM) allowed the mapping of these critical properties. Average surface residual stress varied up to 55% on the upward surface. Also, the residual stress profile on the side of the samples highlighted dependence on the measurement height along the build direction and the build platform location. The latter influence was also identified for Sa results. Therefore, the results bring insights into the process planning relevance for the final residual stress in L-PBF manufactured components.

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Acknowledgments

The authors would like to thank Eng. Alisson Denis Carros Nizes from Thyssenkrupp Brasil Ltda. The authors are grateful to the multiuser central facilities (UFABC) for the experimental support.

Funding

This work was supported by the São Paulo Research Foundation (FAPESP) [Project Grant Numbers #2021/00553-6, #2021/09890-5, and #2022/00616-0]. SFS would like to thank CNPq for the Productive in Science fellowship (#310984/2020-3).

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Authors and Affiliations

  1. Engineering, Modeling and Applied Social Sciences Center, Federal University of ABC, Avenida dos Estados, 5001, Santo André, São Paulo, Brazil

    Amanda Rossi de Oliveira, Sydney Ferreira Santos & Erik Gustavo Del Conte

  2. National Institute of Biofabrication (INCT-BIOFABRIS), Av. Albert Einstein, 500, Campinas, São Paulo, 13083-852, Brazil

    André Luiz Jardini

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  1. Amanda Rossi de Oliveira
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Correspondence to Erik Gustavo Del Conte.

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This invited article is part of a special topical issue of the Journal of Materials Engineering and Performance on Residual Stress Analysis: Measurement, Effects, and Control. The issue was organized by Rajan Bhambroo, Tenneco, Inc.; Lesley Frame, University of Connecticut; Andrew Payzant, Oak Ridge National Laboratory; and James Pineault, Proto Manufacturing on behalf of the ASM Residual Stress Technical Committee.

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de Oliveira, A.R., Santos, S.F., Jardini, A.L. et al. Surface Residual Stress and Roughness Mapping for Different Build Locations in Laser Powder Bed Fusion of Maraging Steel. J. of Materi Eng and Perform 33, 4065–4073 (2024). https://doi.org/10.1007/s11665-024-09194-z

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  • DOI: https://doi.org/10.1007/s11665-024-09194-z

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