Effect of build geometry and orientation on microstructure and properties of additively manufactured 316L stainless steel by laser metal deposition

The effect of build geometry and orientation on the microstructure and mechanical properties of additively manufactured AISI 316L stainless steel was studied. For this an integrated laser metal deposition system was used to build two test blocks, Block 1 and Block 2, such that Block 1 had its longest dimension parallel to the build direction while Block 2 had its longest dimension perpendicular to the build direction. Samples with different orientations with respect to the build direction were extracted from the two blocks and characterized in detail. Block 1 was found to have a coarser defect-free microstructure, while Block 2 had a finer microstructure with extensive inter-track/layer defects. The yield strengths and tensile strengths of Block 2 samples were higher than Block 1 samples, but their strain hardening capacities and ductility values were lower. These differences in microstructure and mechanical properties were shown to be an outcome of the different build rates and consequent thermal histories of the two blocks. In order to explain the variation of yield strength with sample orientation, an alternate measure for grain size called effective grain size was introduced, which revealed the effect of grain orientation on the mean free path for dislocation motion and hence yield/flow stress. Variation of yield strength with the effective grain size was found to follow Hall-Petch behaviour.