Effect of processing parameters and thermal history on microstructure evolution and functional properties in laser powder bed fusion of 316L

In this paper, we explain and quantify the causal effect of processing parameters and part-scale thermal history on the evolution of microstructure and mechanical properties in the laser powder bed fusion additive manufacturing of Stainless Steel 316L components. While previous works have correlated the processing parameters to flaw formation, microstructures evolved, and properties, a missing link is the understanding of the effect of thermal history. Accordingly, tensile test coupons were manufactured under varying processing conditions, and their microstructure-related attributes, e.g., grain morphology, size and texture; porosity; and microhardness were characterized. Additionally, the yield and tensile strengths of the samples were measured using digital image correlation. An experimentally validated computational model was used to predict the thermal history of each sample. The temperature gradients and sub-surface cooling rates ascertained from the model predictions were correlated with the experimentally characterized microstructure and mechanical properties. By elucidating the fundamental process-thermal-structure–property relationship, this work establishes the foundation for future physics-based prediction of microstructure and functional properties in laser powder bed fusion.