Optimizing the properties of metals through rapid production and testing
Optimizing the properties of metals through rapid production and testing lead image
Additive manufacturing (AM) has become a popular process in the alteration of a material’s properties and performance. Past research in this area has involved taking full-density materials and modifying their microstructure to match the properties of conventionally processed materials.
Derby et al. explored the additive manufacturing of 316L stainless steel with the goal of enhancing dynamic properties through modification of the material’s structure.
“We wanted to use the rapid nature of AM to modify the microstructure to optimize properties of interest,” said author Saryu Fensin. “Using this high-throughput method of making and dynamically testing materials allowed us to determine what is important in designing materials for extreme conditions.”
The strength and corrosion resistance of 316L stainless steel made it an ideal candidate for AM research. Although there are many conventional ways to modify the microstructure of this metal, such as casting mold design, thermal heat treatments, and mechanical deformation, adjusting the laser parameters of AM processing allows control over grain size, texture, and dislocation density.
Using additive manufacturing, the authors built a total of 425 hex-nut-shaped samples in one afternoon. To down-select samples for enhanced dynamic testing, they used hardness and density as initial filters. The data from the remaining samples showed a correlation between microstructure and dynamic properties, most notably spall strength, which the team modified through build parameters such as laser power, speed, and hatch spacing.
“There is a need to design stronger and lighter materials for defense and other applications,” said Fensin. “Additive manufacturing presented an opportunity to rapidly modify material microstructure and then evaluate these relationships.”
Source: “Tailoring additive manufacturing to optimize dynamic properties in 316L stainless steel,” by Benjamin K. Derby, Ankur Agrawal, David R. Jones, Reeju Pokharel, Daniel T. Martinez, Ramon Martinez, Janith Wanni, Dan Thoma, and Saryu J. Fensin, Journal of Applied Physics (2025). This article can be accessed at https://doi.org/10.1063/5.0245699 .
