Closed-loop deposition of martensitic stainless steel during laser additive manufacturing to control microstructure and mechanical properties

Abstract A closed-loop laser additive manufacturing (CLAM) system was developed to monitor and control layer-by-layer fabrication via directed energy deposition (DED). The well-modified laser additive manufacturing (LAM) package utilizes a thermal infrared camera and thermal image processing algorithms to extract and control the thermal dynamics of the process, including (i) cooling rate, (ii) melt pool temperature, and (iii) heating rate. Martensitic stainless steel of grade S410-L was used to cumulatively deposit 5 layers on top of each other at different processing conditions without closed-loop control. Significant deviations of cooling rate and melt pool temperature are observed within different layers of a thin-wall structure without feedback control in the open-loop state. To assess the effects of cooling rate control on final LAM properties, three samples with different setpoint cooling rates of 550, 1100, and 1750 °C/s are tested under closed-loop conditions. Microstructural and microhardness maps and profiles of open-loop and closed-loop samples reveal highly uniform and controlled hardness profiles when closed-loop control is applied, in contrast to highly varying properties in samples produce in open-loop operation. The current research results illustrate how one can achieve controlled microstructural characteristics and mechanical properties through real-time control of the cooling rate during the LAM process.