Smart-Alloying enables local modification of the chemical composition of metallic components within additive manufacturing processes. This new method represents an innovative process for localized grading of metallic materials in laser-based additive manufacturing. Smart-Alloying involves applying nanoparticulate alloying elements onto the surfaces of additive manufactured components in precise doses using suspensions. The method is shown here using a laser powder bed fusion (PBF-LB/M) as an example. By coating the base material powder and exposing it to the laser source, localized modifications in chemical composition and altered properties can be achieved. Using a chromium-rich ferritic stainless steel as an example, significant alterations in the fundamental microstructure are attained through localized re-alloying of carbon. Investigation utilizing FIB-SEM elucidate the evolution of increasing carbon content within the re-alloyed area. Next to the formation of chromium-rich carbides and ultrafine regions of needle-like martensite, retained austenite could be made visible. The completely renewed microstructure is then further modified using secondary exposures of the laser source. Under the influence of the subsequent melting process, there is an increasing distribution of the re-alloyed carbon, resulting in a completely new structure of a line-shaped duplex microstructure. The integration of secondary exposure introduces a completely novel aspect, offering the potential to merge localized grading via Smart-Alloying with targeted application of laser parameters.
Keywords
- Additive Manufacturing
- In-Situ Process
- Multi-Material
- Smart-Alloying
- Stainless Steel