Selective laser melting of ultra-high-strength TRIP steel: processing, microstructure, and properties

Abstract

This paper presents results about the influence of the selective laser melting (SLM) process parameters on a FeCr4Mo1V1W8C1 (wt%) alloy regarding microstructure and mechanical behavior. Tailored parameter variation studies were performed to obtain crack-free and highly dense SLM parts. The microstructure was studied using scanning electron microscopy, X-ray diffraction, Auger electron spectroscopy, and scanning transmission electron microscopy. Additionally, the mechanical properties were investigated by compression and tensile tests. The obtained microstructure is composed of complex nanoscale carbides, retained austenite, and martensite. Caused by the fast directional cooling during SLM, a completely dendritic solidification aligned in building direction occurs. Non-equilibrium segregation leads to an orderly phase arrangement of complex carbides at the boundary of the dendrites surrounded by retained austenite and martensite in the center of the dendrites. A strong work hardening behavior was observed, based on an austenite-to-martensite phase transformation (TRIP effect). This effect accounts for the outstanding mechanical properties such as compression strength of 6000 MPa, a 0.2% tensile yield strength of 560 MPa, and an ultimate tensile strength of over 1000 MPa. These findings reveal that SLM is advantageous for the processing of ultra-high-strength FeCrMoVWC tool steel.