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Investigation into the effect of process parameters on density, surface roughness, and mechanical properties of 316L stainless steel fabricated by selective laser melting

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Abstract

Selective laser melting (SLM) process produces high-performance metal parts using a layer-by-layer technique involving various influential factors. Nevertheless, there is a research gap in predictive models for the performance of SLM-processed 316L stainless steel, specifically concerning the effect of process parameters and their interactions. To address this, a systematic approach based on Taguchi design and analysis of variance (ANOVA) was used to optimize the SLM processing of 316L stainless steel. An experimental plan was set up using an L9 orthogonal array, with laser power, hatch spacing, and scan speed as input variables, each with three levels. Optical microscopy was used to analyze microstructure and porosity, while response variables, including relative density, surface roughness, hardness, and tensile properties, were measured. Regression models and response surface method (RSM) contour plots modeling the relationship between the input factors and the response variables were also presented. The main aim of this study is to provide valuable design tools for predicting and optimizing the performance of 316L SS processed by SLM. Results showed high densification levels (up to 99.97%) and excellent mechanical properties, surpassing conventionally processed 316L SS. The sample produced at P = 170W, h = 0.08 mm, and v = 1000 mm/s exhibited the highest tensile properties with a yield strength of 421 MPa, hardness of 245 HV, and elongation at failure of 42%. For the variation range, ANOVA results showed that hatch spacing was the most significant parameter influencing relative density and mechanical properties. The scan speed and hatch spacing increase negatively impacted all properties due to low densification. Moreover, increased laser power can melt the powder, resulting in less porosity. As a result, surface finish and ductility are improved. Overall, the findings of this paper contribute to the fabrication of stainless steel 316L using SLM with optimized parameters.

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Authors and Affiliations

  1. Department of Mathematics, Computer Science and Engineering, University of Quebec at Rimouski, Rimouski, Quebec, G5L 3A1, Canada

    Asma Mansoura, Shayan Dehghan & Noureddine Barka

  2. Department of Mechanical Engineering, University of Quebec at Trois-Rivières, Trois-Rivières, Quebec, G8Z 4M3, Canada

    Sasan Sattarpanah Kangranroudi

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  1. Asma Mansoura
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Conceptualization: Asma Mansoura, Shayan Dehghan, Noureddine Barka, and Sasan Sattarpanah Karganroudi; methodology: Asma Mansoura, Shayan Dehghan, and Noureddine Barka; formal analysis: Asma Mansoura, Shayan Dehghan, and Noureddine Barka; investigation: Asma Mansoura and Shayan Dehghan; resources: Asma Mansoura; data curation: Asma Mansoura and Shayan Dehghan; writing—original draft preparation: Asma Mansoura; writing—review and editing: Asma Mansoura and Shayan Dehghan. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Shayan Dehghan.

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Mansoura, A., Dehghan, S., Barka, N. et al. Investigation into the effect of process parameters on density, surface roughness, and mechanical properties of 316L stainless steel fabricated by selective laser melting. Int J Adv Manuf Technol 130, 2547–2562 (2024). https://doi.org/10.1007/s00170-023-12865-1

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