Effect of Process Parameters on Defects, Melt Pool Shape,Microstructure, and Tensile Behavior of 316

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Previous studies have revealed that laser power and energy density are significant factors affecting the quality of parts manufactured by selective laser melting (SLM).The normalized equivalent density E0* and dimensionless laser power q*,which can be regarded as a progress on the understanding of the corresponding dimensional quantities,are adopted in this study to examine the defects,melt pool shape,and primary dendrite spacing of the SLM-manufactured 316L stainless steel,because it reflects the combined effect of process parameters and material features.It is found that the number of large defects decreases with increasing E0* due to enough heat input during the SLM process,but it will show an increasing trend when excessive heat input (i.e.,utilizing a high E0*) is imported into the powder bed.The q* plays an important role in controlling maximum temperature rising in the SLM process,and in turn,it affects the number of large defects.A large q* value results in a low value of absolute frequency of large defects,whereas a maximum value of absolute frequency of large defects is achieved at a low q* even if E0* is very high.The density of the built parts is greater at a higher q* when E0* remains constant.Increasing the melt pool depth at relatively low value of E0* enhances the relative density of the parts.A narrow,deep melt pool can be easily generated at a high q* when E0* is sufficiently high,but it may increase melt pool instability and cause keyhole defects.It is revealed that a low E0* can lead to a high cooling rate,which results in a refined primary dendrite spacing.Relatively low Eo* is emphasized in selecting the process parameters for the tensile test sample fabrication.It shows that excellent tensile properties,namely ultimate tensile strength,yield strength,and elongation to failure of 773 MPa,584 MPa,and 46%,respectively,can be achieved at a relatively low E0* without heat treatment.
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