Metallographic evaluation of duplex stainless steel powders processed by selective laser melting

Purpose - This paper aims to establish the microstructures and the process-structure relationships in duplex stainless steel powders consolidated by selective laser melting (SLM). Design/methodology/approach - A priori data on energy density levels most appropriate to consolidation of duplex stainless steel powders through SLM served as the basis to converge on the laser settings. Experimental designs with varying laser power and scan speeds and test pieces generated allowed metallographic evaluations based on optical and scanning electron microscopy and electro backscatter diffraction analyses. Findings - Duplex stainless steel powders are established for processing by SLM. However, the dynamic point heat source and associated transient thermal fields affect the microstructures to be predominantly ferritic, with grains elongated in the build direction. Austenite precipitated either at the grain boundaries or as Widmanstatten laths, whereas the crystallographic orientations and the grain growth are affected around the cavities. Considerable CrN precipitation is also evidenced. Originality/value - Duplex stainless steels are relatively new candidates to be brought into the additive manufacturing realm. Considering the poor machinability and other difficulties, the overarching result indicating suitability of duplex powders by SLM is of considerable value to the industry. More significantly, the metallographic evaluation and results of the current research allowed further understanding of the material consolidation aspects and pave ways for fine tuning and establishment of the process-structure-property relationships for this important process-material combination.