Influence of Various Processing Routes in Additive Manufacturing on Microstructure and Monotonic Properties of Pure Iron—A Review-like Study

Abstract

Additive manufacturing processes have attracted broad attention in the last decades since the related freedom of design allows the manufacturing of parts with unique microstructures and unprecedented complexity in shape. Focusing on the properties of additively manufactured parts, major efforts are made to elaborate process-microstructure relationships. For instance, the inevitable thermal cycling within the process plays a significant role in microstructural evolution. Various driving forces contribute to the final grain size, boundary character, residual stress state, etc. In the present study, the properties of commercially pure iron processed on three different routes, i.e., hot rolling as a reference, electron powder bed fusion, and laser powder bed fusion, using different raw materials as well as process conditions, are compared. The manufacturing of the specimens led to five distinct microstructures, which differ significantly in terms of microstructural features and mechanical responses. Using optical and electron microscopy as well as transmission electron microscopy, the built specimens were explored in various states of a tensile test in order to reveal the microstructural evolution in the course of quasistatic loading. The grain size is found to be most influential in enhancing the material’s strength. Furthermore, substructures, i.e., low-angle grain boundaries, within the grains play an important role in terms of the homogeneity of strain distribution. On the contrary, high-angle grain boundaries are found to be regions of strain localization. In summary, a holistic macro-meso-micro-nano investigation is performed to evaluate the behavior of these specific microstructures.