The PBF-LB/M process is highly suitable for the additive manufacturing of complex parts with precise geometrical accuracy using metallic powders. However, certain unknown variables exist within the process. Particularly, the thermal conductivity introduces a significant level of uncertainty due to the substantial impact of heat transfer from the part solid to the bulk material. Insufficient experimental data on the thermophysical properties of powder and a limited understanding of the influencing factors further exacerbate this issue. This study presents the thermophysical properties of steel powders commonly employed in the PBF-LB/M process, utilizing a newly-developed powder container for laser flash analysis. Through a quantitative comparative analysis with the corresponding solid materials, it has been demonstrated that the chemical composition and microstructure play a secondary role in determining the heat conductivity of the powder bed. Instead, it is the powder size distribution that serves as the primary parameter governing the observed behavior. © 2023 Elsevier B.V.

This paper compares, for the first time, laser powder bed fusion (PBF-LB/M) processing of a powder mixture (PM), also known as in-situ alloying, with that of a pre-alloyed (PA) powder from gas atomization with the same chemical composition, using the example of X2CrNiMoN20–10–3 ferritic-austenitic stainless steel. The focus is on the differences in the microstructure formation mechanisms during PBF-LB/M between PM and PA using different energy inputs, in order to gain new insights into the process transferability of in-situ alloying to the processing of pre-alloyed powders. The microstructure investigations are carried out using electron backscattered diffraction (EBSD), energy dispersive (EDS) as well as wavelength dispersive X-ray spectrometry (WDS), X-ray diffraction (XRD) and magneto-inductive method (Feritscope®). The microstructures of samples produced from PM and PA differ significantly in terms of the resulting ferritic and austenitic phase fractions, so that a ferritic-austenitic microstructure forms for PM, while the PA is predominantly austenitic. The differences are mainly based on the increased chemical inhomogeneities for the PM in comparison to the PA state, which are discussed based on EDS map analysis through spatial statistics. With increasing energy input, the chemical homogeneity of the PM approaches that of the PA, but it cannot reach it even with maximum energy input. The formation of a ferritic-austenitic microstructure in the case of the PM leads to the formation of a finer microstructure compared to single-phase PA steel resulting in higher hardness of PBF-LB/M-built PM. © 2023 Elsevier B.V.

PBF-LB/M is the most suitable process for the additive manufacturing with metallic powders when it comes to complex parts with geometrical accuracy. Nevertheless, some unknown variables are present in the process. Especially the thermal conductivity adds a high degree of uncertainty due to the significant influence of the heat flux from the part to the powder bed on the resulting properties of the part. A lack of experimental data addressing the thermophysical properties of powder and a deep understanding of the influences amplifies this problem. This work presents the thermophysical properties of different steel powders commonly used in the PBF-LB/M process using a newly developed powder container. In a quantitative comparative analysis with the corresponding solid materials, it could be shown that chemical composition and microstructure play a subordinate role in the resulting heat conductivity. Instead, the powder size distribution could be identified as the main parameter determining the emerging behavior. © European Powder Metallurgy Association (EPMA)

The influence of heat treatment parameters on the carbide morphology of the powder metallurgic high-speed steel HS 6-5-3-8 is examined. To that end, diverse heat treatment parameters are selected and applied by quenching dilatometry. In particular, different austenitizing temperatures, as well as an isothermal holding stage during quenching in the temperature regime of the transformation gap at temperatures between 450 and 600 °C, are produced. Extensive computer-aided image analysis is performed to investigate the carbide morphology. It is found that the circularity of the tungsten-rich M6C carbides increases significantly after short holding times at a temperature of 550 °C due to the carbide precipitation from metastable and supersaturated austenite onto pre-existing carbides. Longer holding times lead to further growth of the carbides, while the circularity of the carbides does not change. It is further shown that the hardness of the isothermally treated material is increased, all other parameters being equal. Increased carbide circularity might be helpful for increasing the toughness while reaching the same hardness and wear resistance as the conventional heat-treated material. Moreover, it might be possible to enhance the austenitizing temperature with regain of positive carbide morphology properties during the isothermal holding stage. Thus, improved material properties could be achieved. © 2022 The Authors. Steel Research International published by Wiley-VCH GmbH.

In this study, the deformation-induced α-martensite formation in AISI 304L steel was investigated in the temperature range between 75 °C and − 196 °C in the light of the temperature-dependence of hydrogen embrittlement phenomena. For this purpose, tensile tests with in-situ and ex-situ magnetic measurement of the α-martensite volume content as a function of plastic strain were carried out. In addition, a theoretical assessment of the temperature-dependence of the austenite stability was undertaken, evaluating chemical and non-chemical driving force contributions to the martensitic γ → α transformation as proposed by Ghosh and Olson. The experimental results clearly show an increase in the α-martensite volume content and a shifting of the phase transformation to lower strain levels upon reducing the temperature to − 75 °C. A further reduction of the temperature to − 196 °C revealed to have no significant impact on the α-martensite formation. The theoretical assessments indicate a similar temperature-dependence of the austenite stability as observed experimentally and suggest contributions of the thermal friction work at the fcc/bcc interface to be responsible for a constant austenite stability in low-temperature regimes. Additional investigations of deformed microstructures showed that element segregation effects on the local austenite stability are pronounced around room temperature, but become less relevant at low temperatures. © 2023, The Author(s).

Hot isostatic pressing of powder metallurgy tool steels results in high performance tools with outstanding properties. However, the successively deployed conventional heat treatments are not tailored for this manufacturing route, generating room for improvement. This work presents a simulation workflow targeting a twofold optimization of the heat treatment after the consolidation process. These two goals are (i) the improvement of the process stability regarding hardness and chemical variations resulting from the as-delivered condition; and (ii) the determination of the most efficient treatment to guarantee a minimum hardening. The workflow includes calculation of metastable states using Matcalc®, finite element analysis using AbaqusFEA®, and optimization routines written in Python and MATLAB®. To validate the models, a PM X153CrMoV12 ingot was treated in a laboratory furnace, with supporting dilatometry and hardness testing completing the experimental setup. Simulated and measured results agree well, proving the suitability of the workflow for industrial deployment. © European Powder Metallurgy Association (EPMA)

The influence of short-time heat treatment on the widely used and commercially available ledeburitic cold-work tool steel 1.2379 (X153CrMoV12; AISI D2) is examined herein. Starting from a soft annealed initial condition, the influence of different austenitizing temperatures and holding times on the metastable microstructural states after heat treatment/hardening is investigated. The experimental implementation of the heat treatment is used in a quenching dilatometer, and a microstructural simulation model is built using these results. As validation of the model, on the one hand, the martensite start temperature (Ms) is used, measured experimentally by dilatometry. Additionally, the carbide content and distribution, as determined by quantitative image analysis, are compared with the simulated data and used as an indicator of the model accuracy. Through the developed simulation model, arbitrary heat treatment-induced metastable microstructural states can be calculated. As a possible application of this model, the live-adaption of the industrial heat treatment process in dependence on the batch chemical composition is discussed. © 2022 The Authors. Steel Research International published by Wiley-VCH GmbH.

This study presents the development and experimental verification of a simulation model for estimating the local microstructure of a tool geometry after heat treatment. The experiment involved subjecting a metallic block of dimensions 40 × 50 × 50 mm, made of the ledeburitic cold work steel DIN EN 1.2379 (X153CrMoV12; AISI D2), to a heat treatment in a laboratory furnace at 1000 °C for 20 min. Thermocouples were strategically placed to record time-temperature profiles at different locations within the block. Following the heat treatment, the local microstructure was determined through quantitative image analysis, and the local hardness was measured as a function of the distance from the block’s edge to its core. These measurements were then correlated with the corresponding time-temperature curves obtained from the thermocouples. To replicate the local time-temperature profiles, the thermophysical properties of the steel were experimentally determined and incorporated into a finite element analysis heat transfer simulation using Abaqus FEA® software. This simulation approach, combined with the MatCalc software, facilitated the calculation of various local microstructural characteristics such as carbide content, carbide type, carbide distribution, and chemical composition of the matrix. Furthermore, the content fractions of the microconstituents of the matrix, including martensite and retained austenite, were determined based on the simulated martensite start temperature, employing an optimized function fitted to experimental data. The developed simulation model offers potential applications in two important areas. Firstly, it can be used to adapt heat treatment processes for tools of different sizes in production, optimizing their mechanical properties. Secondly, it enables efficient optimization of heat treatment routes by considering changing initial states, leading to high process quality in terms of mechanical properties. Overall, this study provides valuable insights into the estimation and control of local microstructure in tool geometries through the use of a validated simulation model. © 2023, The Author(s).

Introduction: A full three-dimensional (3D) microstructure characterization that captures the essential features of a given material is oftentimes desirable for determining critical mechanisms of deformation and failure and for conducting computational modeling to predict the material’s behavior under complex thermo-mechanical loading conditions. However, acquiring 3D microstructure representations is costly and time-consuming, whereas 2D surface maps taken from orthogonal perspectives can be readily produced by standard microscopic procedures. We present a robust and comprehensive approach for such 3D microstructure reconstructions based on three electron backscatter diffraction (EBSD) maps from orthogonal surfaces of two-phase materials. Methods: It is demonstrated that processing surface maps by spatial correlation functions combined with principal component analysis (PCA) results in a small set of unique descriptors that serve as a representative fingerprint of the 2D maps. In this way, the differences between surface maps of the real microstructure and virtual surface maps of a reconstructed 3D microstructure can be quantified and iteratively minimized by optimizing the 3D reconstruction. Results: To demonstrate the applicability of the method, the microstructure of a metastable austenitic steel in the two-phase region, where austenite and deformation-induced martensite coexist at room temperature, was characterized and reconstructed. After convergence, the synthetic 3D microstructure accurately describes the experimental system in terms of physical parameters such as volume fractions and phase shapes. Discussion: The resulting 3D microstructures represent the real microstructure in terms of their characteristic features such that multiple realizations of statistically equivalent microstructures can be generated easily. Thus, the presented approach ensures that the 3D reconstructed sample and the associated 2D surface maps are statistically equivalent. Copyright © 2023 Eshlaghi, Egels, Benito, Stricker, Weber and Hartmaier.

Hydrogen can drastically degrade the mechanical properties of a variety of metallic materials. The so-called hydrogen environment embrittlement of austenitic CrNi-type steels is usually accompanied by the formation of secondary surface cracks, which can be investigated in order to assess the embrittlement process. The occurrence of hydrogen-induced cracks is often related to element segregation effects that locally impact the austenite stability. Since there is as yet a lack of investigation methods that can visualize both structures three-dimensionally, the present study investigates the imageability of hydrogen-induced cracks and element segregation structures in austenitic CrNi-steel via micro-computed tomography (CT). In order to improve the X-ray visibility of segregation structures, modified versions of the reference steel, X2CrNi18-9, that contain W and Si are designed and investigated. The investigations demonstrated that small differences in the X-ray attenuation, caused by the W or Si modifications, can be detected via CT, although segregation structures could not be imaged due to their small size scale and image noise. Hydrogen-induced cracks were characterized successfully; however, the detection of the smaller cracks is limited by the resolution capability. © 2023 by the authors.

The influence of short-time heat treatment on the widely used and commercially available ledeburitic cold-work tool steel 1.2379 (X153CrMoV12; AISI D2) is examined herein. Starting from a soft annealed initial condition, the influence of different austenitizing temperatures and holding times on the metastable microstructural states after heat treatment/hardening is investigated. The experimental implementation of the heat treatment is used in a quenching dilatometer, and a microstructural simulation model is built using these results. As validation of the model, on the one hand, the martensite start temperature (Ms) is used, measured experimentally by dilatometry. Additionally, the carbide content and distribution, as determined by quantitative image analysis, are compared with the simulated data and used as an indicator of the model accuracy. Through the developed simulation model, arbitrary heat treatment-induced metastable microstructural states can be calculated. As a possible application of this model, the live-adaption of the industrial heat treatment process in dependence on the batch chemical composition is discussed. © 2022 The Authors. Steel Research International published by Wiley-VCH GmbH.