ABSTRACT
The selective laser melting technology is of great interest in the aerospace industry since it allows the implementation of more complex part geometries compared to the traditional technologies. This paper presents the results of studies to determine the optimal technological parameters for scanning a Ni-Cr-Al-Ti-based superalloy. However, due to a large number of factors affecting the quality of the parts obtained by selective laser melting technology, the optimization of the technological parameters of the scanning is a difficult task. In this work, the authors made an attempt to optimize the technological scanning parameters which will simultaneously correspond to the maximum values of the mechanical properties ("More is better") and the minimum values of the dimensions of the microstructure defect ("Less is better"). Gray relational analysis was used to find the optimal technological parameters for scanning. Then, the resulting solutions were compared. As a result of the optimization of the technological parameters of the scanning by the gray relational analysis method, it was found that the maximum values of the mechanical properties were achieved simultaneously with the minimum values of the dimensions of a microstructure defect, at a laser power of 250 W and a scanning speed of 1200 mm/s. The authors present the results of the short-term mechanical tests for the uniaxial tension of the cylindrical samples at room temperature.
ABSTRACT
The freeform capability additive manufacturing (AM) technique and the magnetic efficiency of Fe-6.5Si steel have the potential for the development of electromechanical component designs with thin body sections. Moreover, the directional anisotropy of the material, which is formed during growth, improves the magnetic and electrical properties of Fe-6.5 wt%Si. We obtained the range of optimal technological modes of Laser Power Bed Fusion process (volume energy density (VED) of 100−140 J/mm3, scanning speed of 750−500 mm/s) to produce the samples from Fe-6.5 wt%Si powder, but even at the best of them cracks may appear. The optical microscopy and SEM with EDX analysis of the laser-fabricated structures are applied for investigation of this phenomena. We detected a carbon content at the boundaries of the cracks. This suggests that one of the reasons for the crack formation is the presence of Fe3C in the area of the ordered α'FeSi (B2)+Fe3Si(D03) phases. Quantitative analysis based on crack initiation criteria (CIC) showed that the safe level of internal stresses in terms of the CIC criteria in the area of discontinuities is exceeded by almost 190%. Local precipitates of carbides in the area of cracks are explained by the heterogeneity and high dynamics of temperature fields, as well as the transfer of substances due to Marangoni convection, which, as a result, contributes to a significant segregation of elements and the formation of precipitate phases.
