Effect of processing parameters on the microstructure, mechanical properties and thermal expansion behavior of Invar 36 alloy manufactured by laser powder bed fusion

Abstract

Invar 36 alloy manufactured via the laser powder bed fusion (LPBF) process have attracted interest for their excellent low expansion properties. The properties of Invar 36 alloy, particularly thermal expansion, are highly sensitive to variations in process parameters. However, the effect of process parameters on microstructure and properties has not been systematically studied. This study examines the microstructure, mechanical properties, and coefficient of thermal expansion (CTE) of Invar 36 alloy under various processing parameters with different volumetric energy densities (VED). The results demonstrate that VED variations significantly impact the microstructure, mechanical properties, and CTE. Increasing VED leads to larger grain size and higher high angle grain boundaries, while geometric dislocation density and Taylor factor do not exhibit a linear relationship. At 89.29 J/mm3 VED, the Invar 36 alloy displays the optimal yield strength (405.4 MPa), tensile strength (489.3 MPa), and elongation (43.3%). The CTE meets the ASTM F1684 standard for all specimens. Lower relative density corresponds to smaller CTE, with the lowest CTE achieved at VED of 41.67 J/mm3. Furthermore, the influence of porosity on CTE diminishes with rising temperature. This research opens up the possibility of process parameters optimization for improved CTE and mechanical properties in as-printed Invar parts.