Forming quality control of Laser Powder Bed Fusion GH3536 alloy: Surface quality, defects, and microstructure

Abstract

This study investigates the influence of volume energy density (VED) on surface quality, density, defects, and microstructure of laser powder bed fusion (L-PBF) GH3536 alloy. Specimens fabricated below 80 J/mm3 exhibit lack-of-fusion pores on surfaces and internally, with pore density decreasing but crack initiation occurring as VED increases. Density consistently exceeds 99.5%, peaking at 99.85% (VED = 167 J/mm3). Excessive VED (208 J/mm3) induces surface warping, reduces cracking, but increases pore size/quantity, causing marginal density reduction. Lack-of-fusion defects nucleate microcracks distributed in layer bands; cracks propagate along high-angle grain boundaries following grain growth directions with significant localized stress. Higher VED increases melt pool overlap rate (70.49% at 208 J/mm3) and aspect ratio (width/depth = 6.9), while reducing cooling rates to 1.2 × 105 K/s.

Keywords

GH3536 alloy / Laser powder bed fusion / Surface quality / Defects / Microstructure

Funding

This research is funded by the National Natural Science Foundation of China (grant numbers 52265053, 52361010); the Aeronautical Science Foundation (grant numbers 2022Z049056001, 2023Z049056001); the Natural Science Foundation of Jiangxi Province (grant number 20242BAB25270); the Social Science Foundation Project of Jiangxi Province (grant number 22GL44); the Science and Technology Research Project of Jiangxi Provincial Department of Education (grant number GJJ2201114); and the Natural Science Foundation of Ningbo (grant number 2024J077).

Conflict of Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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