Laser hardening of steel sintered parts

The possibility of applying rapid and localized laser hardening to near-net shape parts, like the ones deriving from powder metallurgy (P/M) is investigated, demonstrating that even low alloyed steels (Fe + 2% Cu + 0,7% C) can be successfully heat treated with minimal or no dimensional variations. Laser hardening conditions have been selected on the basis of the results of the previous research, carried out by means of an Nd-YAG high power system [1]. To avoid some carbon loss, observed on previous activities, the samples have been protected by neutral atmosphere. The microstructural features of the laser hardened steels have been analyzed by optical microscopy, whereas the surface micro-geometry has been characterized by scanning electron microscope. Hardened depth (HD), hardened width (HW) and hardened area (HA) have been measured as well. As expected, the micro-hardness profiles present a sharp drop at low distance from the hardened surface. The typical splitting between hardened zone and heat-Affected zone (HAZ), well known from laser hardened fully dense steels, has been observed also on low-Alloy sintered steels. The use of a protective atmosphere has been helpful to control surface decarburization and to prevent oxidation. The research confirm that Laser transformation Hardening (LTH) is a suitable hardening process of P/M components, through the action of a scanning laser beam. The short heating time and the modest volume fraction structurally modified can contribute to avoid part distortion, in comparison with other hardening methods

Laser Sintering of Stainless Steel using Resin Powder

We tried laser sintering of 316L stainless steel powder using resin powder. The laser sintering conditions such as laser power, scan speed and scan pitch with a YAG laser, and the influence of additional resin powder on the density and the tensile properties of the sintered alloy were investigated experimentally. The tensile specimen was laser-sintered with a YAG laser, and then debound and sintered in a vacuum furnace. The tensile specimen was successfully fabricated. The relative density and the tensile strength varied with the additional resin powder, and the optimum weight percentage of additional resin powder was around 4%.The relative density of the sintered alloy was approximately 85%, and the tensile strength and elongation of the sintered alloy were more than 280 MPa and 15% respectively.Mechanical Engineerin

Amorphous Al-Ti Powders Prepared by Mechanical Alloying and Consolidated by Electrical Resistance Sintering

A novel processing method for amorphous Al50Ti50 alloy, obtained by mechanical alloying and subsequently consolidated by electrical resistance sintering, has been investigated. The characterisation of the powders and the confirmation of the presence of amorphous phase have been carried out by laser diffraction, scanning electron microscopy, X-ray diffraction, differential scanning calorimetry and transmission electron microscopy. The amorphous Al50Ti50 powders, milled for 75 h, have a high hardness and small plastic deformation capacity, not being possible to achieve green compacts for conventional sintering. Moreover, conventional sintering takes a long time, being not possible to avoid crystallisation. Amorphous powders have been consolidated by electrical resistance sintering. Electrically sintered compacts with different current intensities (7–8 kA) and processing times (0.8–1.6 s) show a porosity between 16.5 and 20%. The highest Vickers hardness of 662 HV is reached in the centre of an electrically sintered compact with 8 kA and 1.2 s from amorphous Al50Ti50 powder. The hardness results are compared with the values found in the literature.Ministerio de Economía y Competitividad (Spain) / Feder (EU) DPI2015-69550-C2-1-PMinisterio de Economía y Competitividad (Spain) / Feder (EU) DPI2015-69550-C2-2-

Fatigue response of as built DMLS processed Maraging Steel and effects of machining and heat and surface treatments

The main motivations for this study arise from the need for an assessment of the fatigue performance of DMLS produced Maraging Steel MS1, when it is used in the \u201cas fabricated\u201d state. The literature indicates a lack of knowledge from this point of view, moreover the great potentials of the additive process may be more and more incremented, if an easier and cheaper procedure could be used after the building stage. The topic has been tackled experimentally, investigating the impact of heat treatment, machining and micro-shot-peening on the fatigue strength with respect to the \u201cas built state\u201d. The results indicate that heat treatment significantly enhances the fatigue response, probably due to the relaxation of the post-process tensile residual stresses. Machining can also be effective, but it must be followed (not preceded) by micro-shot-peening, to benefit from the compressive residual stress state generated by the latter

Fabrication Technologies of the Sintered Materials Including Materials for Medical and Dental Application

This chapter of the book presents the basis of classical powder metallurgy technologies and discusses powder fabrication, preparation, preliminary moulding, sintering and finish treatment operations. A general description of the materials and products manufactured with the classical powder metallurgy methods is presented. New variants are characterised along with special and hybrid technologies finding their applications in powder metallurgy. Special attention was drawn to microporous titanium and to TiAl6V4 alloy fabricated using hybrid rapid manufacturing technologies with selective laser sintering/selective laser melting (SLS/SLM) used for innovative implant scaffolds in medicine and regenerative dentistry. Laser deposition, thermal spraying and detonation spraying of powders are also discussed as special methods in which powders of metals and other materials are used as raw materials

Direct Laser Sintering of Metals

The use of a directed laser bealn source to selectively sinter multiple layers of binderless metal powder for the purposes of rapid prototyping is described. The work in this paper is restricted to -325 mesh iron powder, which was sintered using a C\V 50 W Nd:YAG laser to approximately 3.5% density. A subsequent post-treatlnent was perfornled to achieve a fully dense saulple. It is envisioned that such a system can be used to manufacture functional metallic prototypes directly from CAD without part-specific tooling.Mechanical Engineerin

Experimental Investigation on Thermal Diffusivity of PM Steels

The scanty literature data on thermal diffusivity of P/M steels seems contradictory, if the cooling speed on quenching is the evaluation parameter. Due to the basic importance of diffusivity on the response of P/M steels to heat-treating, an experimental survey has been carried out, to collect data on various P/M steels, based on prealloyed, or diffusion-bonded, or admixed powders. The study has also covered the influence of processing parameters, such as compaction pressure and sintering temperature. The flash method has been used to measure the thermal diffusivity of P/M steels. This method directly measures the thermal diffusivity of a sample in slab shape. A plane-parallel sample is inserted in the test apparatus and then a short light pulse, produced by a laser or a flash lamp, heats the front surface of the sample. The heat diffuses through the sample, leading to a temperature rise on the sample rear surface. An infrared detector measures this temperature rise, versus time, and thermal diffusivity is derived from the least square regression on the whole temperature trend, using the analytical solution of heat conduction. The results show that thermal diffusivity increases as density increases. This achievement can be justified by a simple theoretical analysis of the thermal conductivity on thermal diffusivity. The collected data also enable us to ascertain the influence of sintered material composition and carbon content on thermal diffusivity. The results should contribute to clarify some uncertainties and perplexities on the behavior of properly elaborated P/M steels, to be hardened by heat treatment, conventional – such as oil quenching – or innovative, such as sinter -hardening

Powder Deposition and Sintering for a Two-Powder Approach to Solid Freeform Fabrication

A two-powder approach is presented where Fused Deposition modeling (FDM) is used to create a thin shell in the shape of the part to be fabricated. The shell is filled with powder of the part material and surrounded by a support powder that has a high sintering temperature. Upon compressing and sintering the shelVpowder system in a uniaxial hot press, the polymer shell burns out and the support powder compresses the part powder. The part powder consolidates into the desired part while the support material remains in powder form and can be easily removed. This paper presents results ofinitial experimental studies.Mechanical Engineerin

Quantification and characterisation of porosity in selectively laser melted Al–Si10–Mg using x-ray computed tomography

We used X-ray computed tomography (CT), microscopy and hardness measurements to study Al–Si10–Mg produced by selective laser melting (SLM). Specimens were subject to a series of heat treatments including annealing and precipitation hardening. The specimen interiors were imaged with X-ray CT, allowing the non-destructive quantification and characterisation of pores, including their spatial distribution. The specimens had porosities less than 0.1%, but included some pores with effective cross-sectional diameters up to 260 μm. The largest pores were highly anisotropic, being flat and lying in the plane normal to the build direction. Annealing cycles caused significant coarsening of the microstructure and a reduction of the hardness from (114 ± 3) HV, in the as-built state, to (45 ± 1) HV, while precipitation hardening increased this to a final hardness of (59 ± 1) HV. The pore size and shape distributions were unaffected by the heat treatments. We demonstrate the applicability of CT measurements and quantitative defect analysis for the purposes of SLM process monitoring and refinement