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<p>Additive manufacturing (AM), or 3D printing, enables the fabrication of complex and customized components directly from digital models. Despite its advantages, a major challenge is the generation of residual stresses due to the unique thermal cycles in AM processes. These stresses, caused by layer-by-layer material deposition with uneven heating and cooling, can affect the mechanical performance and reliability of parts—potentially leading to distortion, cracking, or failure. In this study, the formation and evaluation of residual stresses in AISI H13 tool steel processed by powder bed fusion with laser beam (PBF-LB) were investigated. The samples were manufactured using a Yb:YAG fiber laser with an 80&#xa0;µm spot size, 172 W power, and 700 mm/s scan speed. Post-processing included quenching followed by either single or double tempering, at temperatures of 650&#xa0;°C and 550&#xa0;°C. Thermodynamic simulations were performed to predict phase formation and physical properties, aiming to assess the impact of phase transformation on volumetric changes and, consequently, on residual stress development. Microstructural analysis and hardness tests were conducted, revealing that double-tempered samples at 550&#xa0;°C exhibited the highest hardness, reaching 665 HV. A recently developed x-ray diffraction method was used to evaluate residual stresses by analyzing 2-theta peak shifts with a 2D detector, allowing for the estimation of lattice parameter changes. Residual stress results were correlated with microstructural features and hardness values. Compressive residual stresses were associated with the formation of fresh martensite from retained austenite and carbide precipitation. Additionally, hardness was strongly correlated with full width at half maximum (FWHM) variation, indicating microstructural refinement. This integrated approach provides valuable insights into the control and prediction of residual stresses in AM components, contributing to the optimization of processing parameters and post-treatment strategies.</p>

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Impact of Heat Treatments on Residual Stress in Additively Manufactured AISI H13 Tool Steel

  • 期刊论文

  • 发表日期：

    2025年6月11日

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  • Fabio Faria Conde,
  • Eduardo B. Fonseca,
  • Suyanny A. Freire,
  • Éder S. N. Lopes

摘要

Additive manufacturing (AM), or 3D printing, enables the fabrication of complex and customized components directly from digital models. Despite its advantages, a major challenge is the generation of residual stresses due to the unique thermal cycles in AM processes. These stresses, caused by layer-by-layer material deposition with uneven heating and cooling, can affect the mechanical performance and reliability of parts—potentially leading to distortion, cracking, or failure. In this study, the formation and evaluation of residual stresses in AISI H13 tool steel processed by powder bed fusion with laser beam (PBF-LB) were investigated. The samples were manufactured using a Yb:YAG fiber laser with an 80 µm spot size, 172 W power, and 700 mm/s scan speed. Post-processing included quenching followed by either single or double tempering, at temperatures of 650 °C and 550 °C. Thermodynamic simulations were performed to predict phase formation and physical properties, aiming to assess the impact of phase transformation on volumetric changes and, consequently, on residual stress development. Microstructural analysis and hardness tests were conducted, revealing that double-tempered samples at 550 °C exhibited the highest hardness, reaching 665 HV. A recently developed x-ray diffraction method was used to evaluate residual stresses by analyzing 2-theta peak shifts with a 2D detector, allowing for the estimation of lattice parameter changes. Residual stress results were correlated with microstructural features and hardness values. Compressive residual stresses were associated with the formation of fresh martensite from retained austenite and carbide precipitation. Additionally, hardness was strongly correlated with full width at half maximum (FWHM) variation, indicating microstructural refinement. This integrated approach provides valuable insights into the control and prediction of residual stresses in AM components, contributing to the optimization of processing parameters and post-treatment strategies.