Laser Powder Bed Fusion printability of cobalt-free steel powders for manufacturing injection molds

Saby, Quentin; Buffière, Jean‐Yves; Maire, Éric; Joffre, Thomas; Bajolet, Julien; Garabedian, Stéphane; Vikner, Peter; Boulnat, Xavier

doi:10.1016/j.addma.2021.102031

Cited by 7 publications

(6 citation statements)

References 38 publications

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“…The previous literature has shown that through the LPBF method, high densities can be obtained [48,55]. Relative densities are more elevated than 99.7% for the samples studied before [48], and the relative porosity does not vary along the construction axis. The porosity profile of the 18Ni300 sample along construction axis Z is illustrated in Figure 6A.…”

Section: Resultsmentioning

confidence: 80%

“…This can cause the beads to have less time to cool between each laser run, potentially contributing to pore formation. It is worth noting that these pores are only visible near the surface of the sample since each layer is printed at a 0° angle with respect to the preceding layer [48]. The presence of internal defects in powders can be attributed to two distinct types of pores-spherical pores resulting from the formation of gas inclusions (complete spherical shapes) or keyholes (semispherical shapes, caused by the union of partial spheres), as shown in Figure 3B, and non-spherical pores arising from a lack of fusion.…”

Section: Resultsmentioning

confidence: 99%

Section: Resultsmentioning

confidence: 99%

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Tomography of Laser Powder Bed Fusion Maraging Steel

Cerezo,

Aguilera,

Garcia-Gonzalez

et al. 2024

Materials

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The presence of defects in additive manufactured maraging steel is a widespread problem as its dependence on processing parameters significantly influences it. Using X-ray computed tomography, along with optical microscope data limited to 2D images, quantifies the internal porosity present on a compact tension sample typically employed in fatigue testing. The primary goal of this research is to analyse the pores obtained after the fabrication of a compact tension sample and their main definition parameters, such as sphericity, aspect ratio, surface, and volume, and obtain validation of which method is valid for each of the parameters analysed. The current study aims to enhance the understanding of defects in maraging steel samples through non-destructive 3D analysis. Conventional 2D analyses are limited to surface measurements, providing incomplete information. The proposed method will provide a comprehensive understanding of the defects inside the maraging steel sample, thereby improving the reliability of this material for further applications. This study will contribute to academic and industrial communities by providing a novel approach to analysing maraging steel samples and, ultimately, developing improved materials for various applications. The study’s findings reveal that most pores are produced by gases that are trapped in the fabrication process, and keyhole pores only appear near the surface.

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Section: Resultsmentioning

confidence: 80%

Section: Resultsmentioning

confidence: 99%

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Tomography of Laser Powder Bed Fusion Maraging Steel

Cerezo,

Aguilera,

Garcia-Gonzalez

et al. 2024

Materials

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“…The Fe-based alloys, which have been extensively studied with L-PBF, include austenitic stainless steels (304L [73,74], 316L [43,75,76], etc), precipitation hardening steels (17-4PH [77,78], 15-5PH [79,80], etc), carbon tool steels (H13 [81,82], etc), and maraging steels (300M [83,84], etc).…”

Section: Fe-based Alloysmentioning

confidence: 99%

Alloy design for laser powder bed fusion additive manufacturing: a critical review

Liu,

Zhou,

Liang

et al. 2024

Int. J. Extrem. Manuf.

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Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM persisted. This is due to the fact that commercial alloys are primarily designed for conventional casting or forging processes, without considering the fast cooling rates, steep temperature gradients, and multiple thermal cycles of L-PBF. To address this, there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies. This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF. It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting the existing alloys for L-PBF. The review begins by discussing the features of L-PBF processes, focusing on rapid solidification and intrinsic heat treatment. Next, the printability of the four main existing alloys (Fe-, Ni-, Al-, and Ti-based alloys) is critically assessed, with a comparison to their conventional weldability. It was found that the weldability criteria are not always applicable in estimating printability. Furthermore, the review presents recent advances in alloy development and associated strategies, categorizing them into crack mitigation-oriented, microstructure manipulation-oriented, and machine learning-assisted approaches. Lastly, an outlook and suggestions are given to highlight the issues that need be addressed in future work.

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“…Figure 1). Maraging 300 (X2NiCoMo18-9-5) is the alloy widely used for this application [8,9] because of its high ductility before heat treatment, its high strength, good hardness [10] and dimensional stability during ageing [11] even though stainless grades are also available for this application [12], [13], [14]. LPBF remains most widely used technology for this application even though Direct Energy Depostion has also been used [15,16,17].…”

Section: Introductionmentioning

confidence: 99%

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

Grosjean

Borneat

Hauteville

et al. 2022

Int J Adv Manuf Technol

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Laser-Powder Bed Fusion is widely used for tooling applications, such as mold insert: conformal cooling channels are designed to decrease cycling time and homogenize the cooling rate. The Achilles' heel of AM mold 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 mold. 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 rst 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 were 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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Laser Powder Bed Fusion printability of cobalt-free steel powders for manufacturing injection molds

Cited by 7 publications

References 38 publications

Tomography of Laser Powder Bed Fusion Maraging Steel

Tomography of Laser Powder Bed Fusion Maraging Steel

Alloy design for laser powder bed fusion additive manufacturing: a critical review

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

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