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Selective Laser Melting of Stainless-Steel: A Review of Process, Microstructure, Mechanical Properties and Post-Processing treatments

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Abstract

Additive Manufacturing (AM) using Selective Laser Melting (SLM) has gained significant prominence across various industries involved in stainless steel part manufacturing. Selective Laser Melting makes it possible to manufacture parts with very complex geometry and with remarkable mechanical and physicochemical properties by controlling the microstructure via the appropriate choice of process parameters. This study presents a comprehensive literature review aiming to provide the scientific and technical communities with an overview of existing knowledge and experimental data regarding the effects of Selective Laser Melting parameters and conditions on the microstructure and mechanical properties of stainless-steel parts. The objective is to highlight the impact of various factors, such as process parameters, building atmosphere, post-heat treatments and initial powder characteristics on phase transformation, porosity and microcracks formation, microstructure evolution and mechanical properties of SLMed stainless steels. Additionally, the integration of emerging Smart Additive Manufacturing (SAM) requires experimental databases, properties prediction and processing parameters optimization to enhance the entire process spanning from design to final product.

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Abbreviations

A(%):

Elongation at break

AI:

Artificial Intelligence

AM:

Additive Manufacturing

D/Z:

Ratio related to the building direction

DLMS:

Direct Laser Metal Sintering

E v :

Volumetric heat input

h:

Hatch distance

Hv:

Vickers hardness

Mf:

Martensite finish temperature

ML:

Machine Learning

Ms:

Martensite start temperature

P:

Laser power

R a :

Average surface roughness

SAM:

Smart Additive Manufacturing

SLM:

Selective Laser Melting

SLS:

Selective Laser Sintering

SPD:

Severe Plastic Deformation

t :

Powder layer thickness

V:

Laser scanning velocity

Z:

Building direction

ρ :

Relative density

σ uts :

Ultimate tensile strength

σ y :

Yield strength

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Authors and Affiliations

  1. University of Tunis (UT), National High School of Engineering of Tunis (ENSIT), Laboratory of Mechanics, Materials and Processes (LMMP-LR-99ES05), 5 Avenue Taha Hussein, 1008, B.P 56, Bab Menara, Tunis, Tunisia

    Thabet A. M. Sghaier & Habib Sahlaoui

  2. University of Tunis El Manar, National Engineering School of Tunis (ENIT), Applied Mechanics and Engineering Laboratory (LMAI-LR-11ES19), BP-37, Le Belvédère 1002, Tunis, Tunisia

    Tarek Mabrouki

  3. HEI-VS, University of Applied Science Western Switzerland HES-SO, Sion, Switzerland

    Haifa Sallem

  4. Université de Lyon, Ecole Centrale de Lyon, ENISE, LTDS, UMR CNRS 5513, 58 Rue Jean Parot, 42000, Saint-Etienne, France

    Joël Rech

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Sghaier, T.A.M., Sahlaoui, H., Mabrouki, T. et al. Selective Laser Melting of Stainless-Steel: A Review of Process, Microstructure, Mechanical Properties and Post-Processing treatments. Int J Mater Form 16, 41 (2023). https://doi.org/10.1007/s12289-023-01769-w

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