PBF-LB Processability, Microstructure and Properties of an Advanced High Strength Powder Steel

Paper in proceeding, 2024

With the advent of additive manufacturing (AM), there is a need for new materials in the field of structural materials. The primary challenge hindering the widespread use of traditional ferrous materials for this purpose is the high carbon content (>0.1%), making the processing difficult. This study aims to explore the processability window and consequent microstructure and properties of a novel low-alloyed steel powder processed using Powder Bed Fusion - Laser Beam (PBF-LB). Process parameters were developed for two different layer thicknesses of 30 and 60 µm to obtain fully dense (~99.9%) and crack free specimens. An in-depth process map was created by characterizing the dimensions and regularity of melt pools using optical microscopy, and further microstructural analysis was carried out using Scanning Electron Microscopy (SEM) revealing the features of a martensitic microstructure. Subsequently, the optimized parameter sets were used to produce tensile and impact testing specimens used to evaluate the mechanical performance of the alloy.