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Combined effect of a spread powder particle size distribution, surface machining and stress-relief heat treatment on microstructure, tensile and fatigue properties of 316L steel manufactured by laser powder bed fusion

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Abstract

Additive manufacturing is a powerful process to build complex geometry. Besides the numerous process parameters influencing the mechanical part performances, other parameters related to the initial powder feedstock or component machining are of most importance. In this study, the combined effect of a wide particle size distribution, surface machining and stress-relief heat treatment on the microstructure and mechanical properties (tension and fatigue) of a stainless steel AISI 316L, produced by laser powder bed fusion, is investigated. In order to correctly investigate those parameters separately, the netshape/machined character of the sample, alongside with the heat treatment, is studied for two kinds of powder having different particle size distributions, i.e. narrow and widely spread. Results show that a large spread of particle size is only slightly detrimental to the fatigue life, in particular in high-cycle conditions due to a larger porosity related to a weakly more uneven particle spatial distribution in the bed. Nevertheless, this effect is of a second order compared to machining or heat treatments which greatly affect the mechanical behaviour. Surface machining and moderate heat treatment are then the best post-operational steps to increase the fatigue life in high-cycle fatigue conditions independently of the particle size distribution. Results are discussed in terms of defects, microstructural modifications, surface roughness, martensitic transformation and mechanical loading.

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Acknowledgements

Yan Duval is acknowledged for the help on the fatigue data treatment. Sebastien Vernay from Normandy Aerospace is also acknowledged for the administrative support on the CLIP FAM project.

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Funding

The Normandy Region and European Union (European Regional Development Fund) are greatly acknowledged for the financial support of the CLIP FAM project.

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Authors and Affiliations

  1. Univ Rouen Normandie, INSA Rouen Normandie, CNRS, Groupe de Physique des Matériaux UMR 6634, F-76000, Rouen, France

    Josiane Nguejio, Morgane Mokhtari, Elie Paccou & Clément Keller

  2. Laboratoire Génie de Production, ENIT-INP, avenue d’Azereix, 65000, Tarbes, France

    Morgane Mokhtari & Clément Keller

  3. Volum-e, Rue de la fonderie, 76340, Blangy-sur-bresle, France

    Eric Baustert

  4. Laboratoire de Mécanique de Normandie, INSA-Rouen Normandie, avenue de l’Université, F-76000, Rouen, France

    Leila Khalij

  5. Laboratoire Crismat, UMR CNRS 6508, ENSICaen, Université de Caen, bvd du maréchal Juin, 14000, Caen, France

    Eric Hug

  6. ArianeGroup, Forêt de Vernon, 27200, Vernon, France

    Pierre Bernard

  7. Laboratoire Analyses et surface, Groupe 6napse, 2 voie de l’innovation, 27100, Val De Reuil, France

    Sébastien Boileau

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Contributions

J. Ngeijio: conceptualisation, investigation, writing and editing. M. Mokhari: conceptualisation, investigation, writing and editing, E. Paccou: investigation. E. Bauster: conceptualisation. L. Khalij: investigation, writing and editing. E. Hug: conceptualisation, writing and editing. P. Bernard: conceptualisation. S. Boileau: conceptualisation, investigation. C. Keller: project supervision, conceptualisation, investigation, writing and editing.

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Nguejio, J., Mokhtari, M., Paccou, E. et al. Combined effect of a spread powder particle size distribution, surface machining and stress-relief heat treatment on microstructure, tensile and fatigue properties of 316L steel manufactured by laser powder bed fusion. Int J Adv Manuf Technol 131, 563–583 (2024). https://doi.org/10.1007/s00170-023-11008-w

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