Experimental Studies on Laser Additive Manufacturing of Inconel-625 Structures Using Powder Bed Fusion at 100 µm Layer Thickness

This paper reports process development and material characterization studies of Inconel-625 (IN625) using laser powder bed fusion (LPBF)-based additive manufacturing at higher layer thickness (100 µm). Conventionally, layer thickness up to 50 µm is used in LPBF due to process instability issues at higher layer thickness. However, successful development of LPBF with higher layer thickness will yield higher build rate. Therefore, systematic parametric investigations are carried out by varying laser power (P), scan speed (v) and hatch spacing (h) from 150 to 450 W, 0.02 to 0.08 m/s and 0.150 to 0.350 mm, respectively, with 100 µm layer thickness. The obtained results are compiled as a function of combined parameter—laser energy density (LED). Samples with relative area density > 99% are achieved for LED of 150, 240 and 360 J/mm³. Geometrical studies show that the deviation from nominal length and range of height of the sample decreases and increases with an increase in LED, respectively. X-ray diffraction shows the presence of face-centered cubic γ-phase at all the conditions with fine crystallites. The microstructure is a mix of cellular and dendritic with the primary arm width increasing with LED. Micro-hardness studies show that the hardness decreases slightly with an increase in LED, while automated ball indentation tests indicate the increase in energy storage capability with increase in LED. The micro-hardness, yield strength and ultimate tensile strength of LPBF built IN625 structure at 100 µm are found to be higher than that of the conventional and laser directed energy deposited IN625 structures and similar to that of the LPBF built IN625 structures at lower layer thickness. The study provides insight into LPBF of IN625 at 100 µm layer thickness and paves way for fabricating components at higher layer thickness with favorable mechanical properties.