Process development and impact of intrinsic heat treatment on the mechanical performance of selective laser melted AISI 4140

Damon, James; Koch, R.; Kaiser, Daniel E.; Graf, Gregor; Dietrich, Stefan; Schulze, Volker

doi:10.1016/j.addma.2019.05.012

Cited by 34 publications

(34 citation statements)

References 18 publications

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“…Thereby, the material undergoes a cyclic change in temperature and varying cooling rates. This is also referred as intrinsic heat treatment and affects the microstructure and mechanical properties of the material [14].…”

Section: Resultsmentioning

confidence: 99%

“…The processability of case hardening steel 16MnCr5 has been studied in detail with the intention to build gear wheels in LPBF [6,7]. Recently, LPBF processing of the steel for quenching and tempering 42CrMo4 (AISI 4140) led to a high part quality with low porosity, no cracking and promising mechanical properties with optimum process parameters [13,14]. In particular, the 30CrNiMo8 steel for quenching and tempering is frequently used for gear wheels and other transmission components.…”

Section: Introductionmentioning

confidence: 99%

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Laser powder bed fusion of 30CrNiMo8 steel for quenching and tempering: examination of the processability and mechanical properties

2020

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The layer-by-layer principle of additive manufacturing technology laser powder bed fusion (LPBF) opens up completely new possibilities in the design and manufacturing of lightweight and efficient gear components. For example, integration of contour conform cooling and lubrication channels into gear components can increase their service life and reduce lubricant consumption. Steels for quenching and tempering and case hardening steels are commonly used materials for gear components. However, the availability of these alloys for LPBF processing is still limited. In particular, the 30CrNiMo8 steel for quenching and tempering is frequently used for gear wheels. This specific alloy is largely unknown regarding LPBF processing and remains challenging, because of its susceptibility to cracking and the high temperature gradients that occur during the LPBF process. Therefore, this study focuses on the LPBF processing of 30CrNiMo8 powder material including process parameter evaluation and material characterization. Additionally, effects of the heat treatment on the resulting microstructure and mechanical properties were investigated. Within this study the 30CrNiMo8 has been processed successfully with a density of well above 99.5% leading to promising mechanical properties. A more homogenous microstructure has been achieved with quenching and tempering, compared to the as-build state.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Laser powder bed fusion of 30CrNiMo8 steel for quenching and tempering: examination of the processability and mechanical properties

2020

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“…In this study, defects were identified as cracks if the perpendicular Feret’s diameter was at least four times the horizontal Feret’s diameter. This method is based on the evaluation criteria applied by Damon et al [ 44 ]. For microstructure analysis, a Zeiss Ultra Plus scanning electron microscope (SEM) equipped with a Digiview 5 detector for electron backscatter diffraction (EBSD) and an OCTANE PRO detector for energy-dispersive X-ray spectroscopy (EDS) was used (both detectors: EDAX, AMATEK Inc., USA).…”

Section: Methodsmentioning

confidence: 99%

Requirements for Processing High-Strength AlZnMgCu Alloys with PBF-LB/M to Achieve Crack-Free and Dense Parts

et al. 2021

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Processing aluminum alloys employing powder bed fusion of metals (PBF-LB/M) is becoming more attractive for the industry, especially if lightweight applications are needed. Unfortunately, high-strength aluminum alloys such as AA7075 are prone to hot cracking during PBF-LB/M, as well as welding. Both a large solidification range promoted by the alloying elements zinc and copper and a high thermal gradient accompanied with the manufacturing process conditions lead to or favor hot cracking. In the present study, a simple method for modifying the powder surface with titanium carbide nanoparticles (NPs) as a nucleating agent is aimed. The effect on the microstructure with different amounts of the nucleating agent is shown. For the aluminum alloy 7075 with 2.5 ma% titanium carbide nanoparticles, manufactured via PBF-LB/M, crack-free samples with a refined microstructure having no discernible melt pool boundaries and columnar grains are observed. After using a two-step ageing heat treatment, ultimate tensile strengths up to 465 MPa and an 8.9% elongation at break are achieved. Furthermore, it is demonstrated that not all nanoparticles used remain in the melt pool during PBF-LB/M.

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“…Low-alloy steels are also potentially attractive due to their low cost and tunable mechanical properties especially after the hardening treatment of quench and tempering (Q & T). Even though low-alloy steels are widely used for structural applications in several industrial sectors, a fairly low number of investigations have been carried out so far on their properties after L-PBF processing [ 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 ]. The available information showed that the L-PBF processed steels in as-built condition provide outstanding mechanical properties.…”

Section: Introductionmentioning

confidence: 99%

On the Recycling of Water Atomized Powder and the Effects on Properties of L-PBF Processed 4130 Low-Alloy Steel

et al. 2022

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The microstructure and mechanical properties of a 4130-grade steel processed by L-PBF using a feedstock of low-cost water atomized powder have been investigated considering the effects of powder recycling. Chemical analysis of the recycled powder showed a constant amount of alloying elements with a slight reduction in oxygen content. The as-built microstructure was mainly composed of a martensitic structure separated by a high fraction of low-angle grain boundaries, suggesting the application of a direct tempering treatment starting from the as-built condition as a cost-effective post-process thermal treatment rather than the conventional quench and tempering treatment. Moreover, the degree of anisotropy generated by L-PBF in as-built specimens could be reduced after performing either the direct tempering or the quench and tempering treatments. The possible degradation of powder properties on the steel performance was also investigated. After various powder recycling events, no significant deterioration in tensile properties was measured, indicating that the water atomized powder could be a sustainable feedstock candidate for L-PBF.

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Process development and impact of intrinsic heat treatment on the mechanical performance of selective laser melted AISI 4140

Cited by 34 publications

References 18 publications

Laser powder bed fusion of 30CrNiMo8 steel for quenching and tempering: examination of the processability and mechanical properties

Laser powder bed fusion of 30CrNiMo8 steel for quenching and tempering: examination of the processability and mechanical properties

Requirements for Processing High-Strength AlZnMgCu Alloys with PBF-LB/M to Achieve Crack-Free and Dense Parts

On the Recycling of Water Atomized Powder and the Effects on Properties of L-PBF Processed 4130 Low-Alloy Steel

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