Investigation of the influence of physical and mechanical characteristics of steel produced by selective laser melting

Аuthors

Tereshchenko T. S.^*, Orekhov A. A.^**, Rabinsky L. N.

Moscow Aviation Institute (National Research University), 4, Volokolamskoe shosse, Moscow, А-80, GSP-3, 125993, Russia

*e-mail: tereschenkots@mai.ru
**e-mail: a_orekhov@mai.ru

Abstract

This study investigates the microstructure and mechanical properties of stainless steel samples fabricated using layer-by-layer laser synthesis. This additive manufacturing method allows for complex geometries but introduces microstructural variations that may impact material performance. Mechanical properties were evaluated through impact bending, tensile, and static bending tests. The results showed that the fabricated samples exhibit stable mechanical characteristics, with ultimate tensile strength and yield strength exceeding standard values for the given steel grade. However, the Young’s modulus, obtained from tensile and bending tests, was significantly lower than the typical values for stainless steel. This reduction may be attributed to microstructural anisotropy, porosity, or residual stresses introduced during the fabrication process. Fractographic analysis using scanning electron microscopy (SEM) revealed a mixed brittle-ductile fracture mode, with brittle fracture predominating. This suggests the presence of microstructural defects such as interlayer boundaries, porosity, or microcracks formed during laser sintering. These defects can reduce fracture toughness and plasticity, making the material more susceptible to brittle failure under certain loading conditions. To further investigate the composition and structural integrity of the material, micro-X-ray spectral analysis was performed. The results confirmed that the chemical composition of the samples fully complies with stainless steel standards, indicating that deviations in mechanical performance arise from microstructural factors rather than material composition. These findings highlight the importance of a comprehensive approach to evaluating materials produced via additive manufacturing. While laser-sintered stainless steel can achieve high strength, its reduced modulus and increased brittleness necessitate careful optimization of processing parameters. Controlling factors such as scanning strategy, heat input, and post-processing treatments could mitigate defects, reduce anisotropy, and improve mechanical properties. Future research should focus on establishing correlations between fabrication parameters, heat treatment, and final material properties. In particular, refining laser sintering parameters and introducing post-processing techniques such as heat treatment or hot isostatic pressing may enhance mechanical performance and structural reliability. These optimizations would enable broader applications of additive manufacturing for load-bearing and high-performance components in industries such as aerospace, automotive, and biomedical engineering.

Keywords:

selective laser melting, stainless steel, mechanical tests, microstructure, micro-X-ray spectral analysis

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