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Effects of channel contour laser strategies on fatigue properties and residual stresses of laser powder bed printed maraging steel

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Abstract

Laser powder bed fusion is widely used for tooling applications, such as mould insert: conformal cooling channels are designed to decrease cycling time and homogenize the cooling rate. The Achilles’ heel of additive manufacturing mould is the cooling channels close to the surface which generate high stress concentration and are not machined; as a result, they create weaknesses in the part and are likely to reduce the lifespan of the mould. It is necessary to study the impact of such channels on properties (fatigue, residual stresses, microstructure) and determine optimized laser strategies to reduce porosity that may occur near a contour. Residual stresses were first estimated above an internal channel after different heat treatments, and fatigue specimens were printed with a 3-mm diameter channel on an EOS M270 printer using different strategies such as several contours with a concentric offset. The impact of these strategies on fatigue properties was analysed through microstructural observations. Here, it was found that a double contour with an offset improved the fatigue life of the part by more than 10 times compared to the standard single contour strategy.

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The authors confirm that the data supporting the findings of this study are available within the article.

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Funding

The research was supported internally by IPC and the CETIM: the authors did not receive any external funding.

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Authors and Affiliations

  1. Cetim - Centre Technique Des Industries Mécaniques, 7 rue de la presse, 42000, St Etienne, France

    Christophe Grosjean

  2. IPC - Centre Technique Industriel de La Plasturgie Et Des Composites, 2 rue Pierre et Marie Curie, 01100, Bellignat, France

    Jean-Christophe Borneat & Thomas Joffre

  3. Cetim - Centre Technique Des Industries Mécaniques, 52 Avenue Félix Louat, 60300, Senlis, France

    Robin Hauteville & Fabien Lefebvre

Authors
  1. Christophe Grosjean
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  2. Jean-Christophe Borneat
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  3. Robin Hauteville
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  4. Fabien Lefebvre
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  5. Thomas Joffre
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All the authors have contributed to the design of the study and to the writing process of this manuscript.

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Correspondence to Thomas Joffre.

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Grosjean, C., Borneat, JC., Hauteville, R. et al. Effects of channel contour laser strategies on fatigue properties and residual stresses of laser powder bed printed maraging steel. Int J Adv Manuf Technol 123, 3109–3120 (2022). https://doi.org/10.1007/s00170-022-10246-8

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  • DOI: https://doi.org/10.1007/s00170-022-10246-8

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