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The material extrusion (MEX) method utilizing highly filled metal filament presents an alternative to advanced additive metal manufacturing technologies. This process enables the production of metal objects through deposition and sintering, which is particularly attractive compared to powder bed fusion (PBF) technologies employing lasers or high-power electron beams. PBF requires costly maintenance, skilled operators, and controlled process conditions, whereas MEX does not impose such requirements. This study compares research on 17-4 PH steel manufactured using two different commercially available techniques: MEX and powder bed fusion with laser beam melting (PBF-LB/M). This research included assessing the density of printed samples, analyzing surface roughness in two printing planes, examining microstructure including porosity and density determination, and measuring hardness. The conducted research aimed to determine the durability and quality of the obtained samples and to evaluate their strength. The research results indicated that samples produced using the PBF-LB/M technology exhibited better density and a more homogeneous structure. However, MEX samples exhibited better strength properties (hardness).
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The aim of this paper is to investigate the factors (build orientation, sample conditions, and R-ratio) that affect the cyclic response of laser powder-bed fusion stainless steel 316L and 17-4 PH parts. Initially, the data set was analyzed to confirm the normality assumption. The significant and insignificant factors that affect the fatigue life were identified using analysis of variance (ANOVA). Main effects for different sample conditions were also analyzed. Process and reproducibility assessment were performed to study the effect of process factors. Combining fatigue data sets was recommended as the best approach to accurately predict the fatigue behavior of LPBF 316L and 17-4 PH parts. Finally, the effect of sample conditions on fatigue life was quantified. The highest fatigue life was achieved with Machined-Polished surfaces.
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The creep response of the 17-4PH martensitic age-hardening steel in H1150 state was investigated at 427 and 482 °C. Hardness measurements of the heads of the creep samples demonstrated that the material underwent additional age hardening during the high-temperature exposure. Microstructural investigations confirmed that the additional precipitation of carbides and the G-phase occurred at the lowest temperature. A set of constitutive equations previously developed to describe the creep response of particle-strengthened alloys was successfully used to obtain a comprehensive description of the experimental data. The value of the particle strengthening term was obtained from the hardness measurements and corresponded to the Orowan stress. The model accurately described the observed minimum creep rate dependence on the applied stress and explained the occurrence of lower values of the minimum strain rate observed during variable-load experiments.
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The growing demand for modern steels showing corrosion and tribological resistance has led to their increased use in the production of medical devices. This study analyzed the effect of shot peening on wear resistance in 0.9% NaCl solution of 17-4PH steel produced by direct laser metal sintering (DMLS) technology. The study's novelty relies on revealing the effect of shot peening (SP) surface treatment on the wet sliding wear resistance of 17-4PH steel produced with DMLS. Moreover, in the context of 17-4PH steel application for medical devices, the 0.9% NaCl tribological environment were selected, and SP processes were conducted using steel CrNi shot and ceramic (ZrO2) beads. The up-to-date scientific literature has not identified these gaps in the research. DMLS technology makes it possible to obtain products with complex architectures, but it also faces various challenges, including imperfections in the surface layer of products due to the use of 3D printing technology itself. The chemical and phase composition of the materials obtained, Vickers hardness, surface roughness, and microscopic and SEM imaging were investigated. Tribological tests were carried out using the ball-on-disc method, and the surfaces that showed traces of abrasion to identify wear mechanisms were subjected to SEM analysis. The XRD phase analysis indicates that austenite and martensite were found in the post-production state, while a higher martensitic phase content was found in peened samples due to phase transformations. The surface hardness of the peened samples increased by more than double, and the post-treatment roughness increased by 12.8% after peening CrNi steels and decreased by 7.8% after peening ZrO2 relative to the reference surfaces. Roughness has an identifiable effect on sliding wear resistance. Higher roughness promotes material loss. After the SP process, the coefficient of friction increased by 15.5% and 20.7%, while the wear factor (K) decreased by 25.9% and 32.7% for the samples peened with CrNi steels and ZrO2, respectively. Abrasive and adhesive mechanisms were dominant, featured with slight fatigue. The investigation showed a positive effect of SP on the tribological properties of DMSL 17-4PH.
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This study investigates the tensile behaviors of additively manufactured (AM) 17-4PH stainless steels heat-treated within various temperature ranges from 400 °C to 700 °C in order to identify the effective aging temperature. Despite an aging treatment of 400-460 °C increasing the retained austenite content, an enhancement of the tensile properties was achieved without a strength-ductility trade-off owing to precipitation hardening by the Cu particles. Due to the intricate evolution of the microstructure, aging treatments above 490 °C led to a loss in yield strength and ductility. A considerable rise in strength and a decrease in ductility were brought about by the increase in the fraction of precipitation-hardened martensitic matrix in aging treatments over 640 °C. The impact of heat-treatment pathways on aging effectiveness and tensile anisotropy was then examined. Direct aging at 482 °C for an hour had hardly any effect on wrought 17-4PH, but it increased the yield strength of AM counterparts from 436-457 to 588-604 MPa. A solid-solution treatment at 1038 °C for one hour resulted in a significant drop in the austenite fraction, which led to an increase in the yield (from 436-457 to 841-919 MPa) and tensile strengths (from 1106-1127 to 1254-1256 MPa) with a sacrifice in ductility. Improved strength and ductility were realized by a solid-solution followed by an aging treatment, achieving 1371-1399 MPa. The tensile behaviors of AM 17-4PH were isotropic both parallel and perpendicular to the building direction.
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In order to improve the performance of 17-4PH under wear conditions (e.g., gears, etc.) and reduce the cost of metal additive manufacturing, TiC needs to be added to 17-4PH to improve its wear resistance. Micron-sized TiC-reinforced 17-4PH stainless steel composites with different contents (0-15 wt%) have been prepared by fused filament fabrication 3D printing for the first time. The effects of TiC content on the structure and properties of composites were studied by XRD, SEM, and sliding wear. The obtained results show that the microstructure of TiC-reinforced 17-4PH stainless steel composites mainly consists of austenite. With the increase in TiC content, the grain size is obviously refined, and the average grain size decreases from 65.58 µm to 19.41 µm. The relative densities of the composites are maintained above 95% with the addition of TiC. The interfaces between TiC particles and the 17-4PH matrix are metallurgical bonds. The hardness of the composites increases and then decreases with increasing TiC content, and the maximum hardness (434 HV) is obtained after adding 10 wt.% of TiC content. The wear rate of the composites was reduced from 2.191 × 10-5 mm3 /(Nâ§m) to 0.509 × 10-5 mm3 /(Nâ§m), which is a 3.3-fold increase in wear resistance. The COF value declines with the addition of TiC. The reasons for the significant improvement in the composites' performance are fine grain strengthening, solid solution strengthening, and second phase strengthening. The wear mechanisms are mainly abrasive and adhesive wear. Compared to the 10 wt% TiC composites, the 15 wt% TiC composites show limited improvement in wear resistance due to more microcracks and TiC agglomeration.
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17-4PH martensitic steel is usually used as valve stems in nuclear power plants and it suffers from thermal aging embrittlement due to long-time service in a high-temperature and high-pressure environment. Here, we characterized the evolution of microstructures at the nano-scale in 17-4PH steel by in situ small-angle neutron scattering (SANS) with a thermo-mechanically coupled loading device. The device could set different temperatures and tensile so that an in situ SANS experiment could dynamically characterize the process of nanoscale structural changes. The results showed that with increasing thermal aging time, the ε-Cu phase precipitates and grows as the temperature is 475 °C and 590 °C, and the ε-Cu phase is spherical at 475 °C but became elongated cylinders at 590 °C. Moreover, the loading stress could aid in the growth of the ε-Cu phase at 475 °C.
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Aging is indispensable for balancing the strength and ductility of selective laser melted (SLM) precipitation hardening steels. This work investigated the influence of aging temperature and time on the microstructure and mechanical properties of SLM 17-4 PH steel. The 17-4 PH steel was fabricated by SLM under a protective argon atmosphere (99.99 vol.%), then the microstructure and phase composition after different aging treatments were characterized via different advanced material characterization techniques, and the mechanical properties were systematically compared. Coarse martensite laths were observed in the aged samples compared with the as-built ones, regardless of the aging time and temperature. Increasing the aging temperature resulted in a larger grain size of the martensite lath and precipitation. The aging treatment induced the formation of the austenite phase with a face-centered cubic (FCC) structure. With prolonged aging treatment, the volume fraction of the austenite phase increased, which agreed with the EBSD phase mappings. The ultimate tensile strength (UTS) and yield strength gradually increased with increasing aging times at 482 °C. The UTS reached its peak value after aging for 3 h at 482 °C, which was similar to the trend of microhardness (i.e., UTS = 1353.4 MPa). However, the ductility of the SLM 17-4 PH steel decreased rapidly after aging treatment. This work reveals the influence of heat treatment on SLM 17-4 steel and proposes an optimal heat-treatment regime for the SLM high-performance steels.
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Additive Manufacturing (AM) has spread significantly in recent years, with relevant applications in many fields of research and engineering. Thanks to its distinctive production methods, AM enables the creation of parts with complex shapes that cannot be fabricated easily by employing traditional subtractive processes. 3D printing, which involves overlapping material layer by layer until the designed part is completed, shows several advantages in terms of limiting material waste, reducing production phases and postprocessing/heat treatments needs, leading to an additional benefit in terms of environmental sustainability. However, there are still limited available data on the influence of the 3D printing process on the mechanical properties of the materials that are commonly used and additional investigations are strongly demanded. So, the purpose of the present paper is to provide a useful contribution in the field of metal additive manufacturing, reporting the results of an experimental campaign carried out on 17-4 P H stainless steel, produced using selective laser melting technology. The effects of different printing orientations and scanning times on the tensile behaviour, impact strength and microhardness features of the 3D-printed products are investigated. Furthermore, the influence of an annealing heat treatment on the material mechanical performance is evaluated.
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This article presents the results of a study on the distribution of weld distortion in thin-walled components made of 17-4 PH steel, resulting from TIG (Tungsten Inert Gas) welding. Both manual and automatic welding processes were examined. Physical simulation of the automated welding process was conducted on a custom-built welding fixture. Analysis of weld distortion in thin-walled components made of 17-4 PH steel was based on the results of measurements of transverse shrinkage and displacement angle values. These measurements were taken on thin-walled parts before and after the welding process using a coordinate measuring machine (CMM). To determine the effect of manual and automated welding processes on the microstructure of the welded joint area, metallographic tests and hardness measurements were performed. The microstructure was analyzed using a scanning electron microscope (SEM). An analysis of the chemical composition of selected welded joint zones was also conducted. These tests were performed using an optical emission spectrometer (OES). According to the results, the use of automated welding and special fixtures for manufacturing thin-walled aircraft engine components made of 17-4 PH steel reduces the propensity of these components for distortion due to the effects of the thermal cycle of the welding process. This conclusion is supported by the results of the observation of the microstructure and analysis of the chemical composition of the various zones of the welded joint area.
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The development of robust and efficient methods for constructing and joining complex metal specimens with high bonding quality and durability is of paramount importance for various industries, e.g., aerospace, deep space, and automobiles. This study investigated the fabrication and characterization of two types of multilayered specimens prepared by tungsten inert gas (TIG) welding: Ti-6Al-4V/V/Cu/Monel400/17-4PH (Specimen 1) and Ti-6Al-4V/Nb/Ni-Ti/Ni-Cr/17-4PH (Specimen 2). The specimens were fabricated by depositing individual layers of each material onto a Ti-6Al-4V base plate, and subsequently welding them to the 17-4PH steel. The specimens exhibited an effective internal bonding without any cracks, accompanied by a high tensile strength, with Specimen 1 exhibiting a significantly higher tensile strength than Specimen 2. However, the substantial interlayer penetration of Fe and Ni in the Cu and Monel layers of Specimen 1 and the diffusion of Ti along the Nb and Ni-Ti layers in Specimen 2 resulted in a nonuniform elemental distribution, raising concerns about the lamination quality. This study successfully achieved elemental separation of Fe/Ti and V/Fe, which is vital for preventing the formation of detrimental intermetallic compounds, particularly in the fabrication of complex multilayered specimens, representing the prime novelty of this work. Our study highlights the potential of TIG welding for the fabrication of complex specimens with high bonding quality and durability.
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The press and sinter method remains the standard among powder metallurgy processes for powdered stainless-steel materials. It delivers low cost, low oxidation rate, and adequate corrosion resistance. Furthermore, 17-4PH is a martensitic stainless-steel that is commonly used for high-strength and medium-ductility stainless steel parts. However, a few studies have investigated the press and sinter method for producing 17-4PH parts. This shortage is due to the high hardness (low compressibility) of 17-4PH powder. Thus, the main objective of this study is to evaluate the press and sinter method in terms of the manufacturing process, the influencing factors, and the theoretical basis of press and sinter methods in conjunction with metal injection molding technology for the production of 17-4PH parts. First, the literature and monographs are examined and summarized to cover the previous results, research progress, development trends, and applications of press and sinter method 17-4PH parts. Following the theoretical analysis, the practical investigation was conducted by producing parts with cold pressing from 800 to 1600â MPa, followed by sintering: the sintering temperature was 1200 °C for one hour under a protective vacuum atmosphere. ImageJ analysis was performed to measure the sinter density. The results showed an increase in relative sinter density from 84.43% to 96.43% for 800 and 1600â MPa, respectively, while the earlier results reached 93.47%. Overall, the press and sinter method enables the production of high-hardness 17-4PH parts with a high density, without using additives like lubricants, wax, or alloying elements.
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Metal additive manufacturing (AM) has been evolving in response to industrial and social challenges. However, new materials are hindered in these technologies due to the complexity of direct additive manufacturing technologies, particularly selective laser melting (SLM). Stainless steel (SS) 316L, due to its very low carbon content, has been used as a standard powder in SLM, highlighting the role of alloying elements present in steels. However, reliable research on the chemical impact of carbon content in steel alloys has been rarely conducted, despite being the most prevalent element in steel. Considering the temperatures involved in the SLM process, the laser-powder interaction can lead to a significant carbon decrease, whatever the processing atmosphere. In the present study, four stainless steels with increasing carbon content-AISI 316L, 630 (17-4PH), 420 and 440C-were processed under the same SLM parameters. In addition to roughness and surface topography, the relationship with the microstructure (including grain size and orientation), defects and mechanical properties (hardness and tensile strength) were established, highlighting the role of carbon. It was shown that the production by SLM of stainless steels with similar packing densities and different carbon contents does not oblige the changing of processing parameters. Moreover, alterations in material response in stainless steels produced under the same volumetric energy density mainly result from microstructural evolution during the process.
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Currently, laser surface treatment (LST) is considered the most promising method available within the industry. It delivers precise control over surface topography, morphology, wettability, and chemistry, making the technique suitable for regulating the corrosion behavior of alloys. In this paper, femtosecond laser texturing with different parameters and atmosphere environments was adopted to clarify the effect of surface treatment on the corrosion resistance of selective laser melted (SLM-ed) 17-4PH stainless steel (SS) in a NaCl solution. The experimental results show that, after the heat treatment, the corrosion resistance of the laser-treated samples was enhanced. With the further laser treatment in an argon atmosphere, the oxidation of nanostructural surfaces was avoided. The Cr, Cu, and other alloying elements precipitated on the laser-ablated surface were beneficial to the formation of a passivation film, leading to an improved corrosion resistance performance.
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In this research, we investigated the influence of the sintering temperature on the physical and mechanical properties of micro-sized bi-material components of 17-4PH stainless steel and 3 mol% yttria-stabilized zirconia fabricated using a two-component micro-powder injection molding (2C-µPIM) process. First, 17-4PH and zirconia powders were separately mixed with binders to obtain feedstocks, which were then injection-molded into the dumbbell shape, followed by the binder extraction process. Subsequently, the debound micro-specimens were subjected to sintering between 1250 °C and 1350 °C for 3 h. Per the observations of the microstructures using scanning electron microscopy (SEM), a strong bond between metal and ceramic in micro-sized 17-4PH/zirconia components was formed when the sintering temperature exceeded 1300 °C. The maximum relative density of 99% was achieved when the bi-material micro-part was sintered at 1350 °C. The linear shrinkage increased from 9.6% to 17.4% when the sintering temperature was increased from 1250 °C to 1350 °C. The highest hardness value of 1439.6 HV was achieved at 1350 °C along the bi-material bonding region. Moreover, a maximum tensile strength of 13.7 MPa was obtained at 1350 °C.
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Laser metal deposition (LMD) is one of the manufacturing processes in the industries, which is used to enhance the properties of components besides producing and repairing important engineering components. In this study, Stellite 6 was deposited on precipitation-hardened martensitic stainless steel (17-4 PH) by using the LMD process, which employed a pulsed Nd:YAG laser. To realize a favor deposited sample, the effects of three LMD parameters (focal length, scanning speed, and frequency) were investigated, as well as microstructure studies and the results of a microhardness test. Some cracks were observed in the deposited layers with a low scanning speed, which were eliminated by an augment of the scanning speed. Furthermore, some defects were found in the deposited layers with a high scanning speed and a low frequency, which can be related to the insufficient laser energy density and a low overlapping factor. Moreover, various morphologies were observed within the microstructure of the samples, which can be attributed to the differences in the stability criterion and cooling rate across the layer. In the long run, a defect-free sample (S-120-5.5-25) possessing suitable geometrical attributes (wetting angle of 57° and dilution of 25.1%) and a better microhardness property at the surface (≈335 Hv) has been introduced as a desirable LMDed sample.
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17-4PH stainless steel specimens were fabricated by fused deposition of metals (FDMet) technology, which combines 17-4PH particles with an organic binder. FDMet promises a low-cost additive manufacturing process. The present research aims to clarify the influence of layer directions in the 3D printing process on the mechanical and shrinkage properties of as-sintered and as-aged specimens. All specimens (the as-sintered and as-aged specimens printed in three layer directions) exhibited high relative density (97.5-98%). The highest ultimate strengths (880 and 1140 MPa in the as-sintered and as-aged specimens, respectively) were obtained when the layer direction was perpendicular to the tensile direction. Conversely, the specimens printed with their layer direction parallel to the tensile direction presented a low ultimate strength and low strain at breakage. The fact that the specimens with their layer direction parallel to the tensile direction presented a low ultimate strength and low strain at breakage is a usual behavior of parts obtained by means of FDM. The SEM images revealed oriented binder domains in the printed parts and oriented voids in the sintered parts. It was assumed that large binder domains in the filament were oriented perpendicular to the layer directions during the fused deposition modeling printing, and remained as oriented voids after sintering. Stress concentration in the oriented void defects was likely responsible for the poor tensile properties of these specimens.
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In the fabrication of 17-4 PH by laser powder bed fusion (L-PBF) the well-documented occurrence of large amounts of retained austenite can be attributed to an elevated concentration of nitrogen present in the material. While the effects of continuous wave (CW) laser processing on in-situ nitrogen absorption characteristics have been evaluated, power modulated pulsed wave (PW) laser processing effects have not. In this study the effects of PW L-PBF processing of 17-4 PH on nitrogen absorption, phase composition, and mechanical performance are explored using commercially available PW L-PBF equipment and compared to samples produced by CW L-PBF. PW L-PBF samples fabricated in cover gas conditions with varying amounts of nitrogen demonstrated reduced absorption levels compared to those produced by CW L-PBF with no effects on phase composition and minimal effects on mechanical performance.
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Fused filament fabrication (FFF) combined with debinding and sintering could be an economical process for three-dimensional (3D) printing of metal parts. In this paper, compounding, filament making, and FFF processing of feedstock material with 55% vol. of 17-4PH stainless steel powder in a multicomponent binder system are presented. The experimental part of the paper encompasses central composite design for optimization of the most significant 3D printing parameters (extrusion temperature, flow rate multiplier, and layer thickness) to obtain maximum tensile strength of the 3D-printed specimens. Here, only green specimens were examined in order to be able to determine the optimal parameters for 3D printing. The results show that the factor with the biggest influence on the tensile properties was flow rate multiplier, followed by the layer thickness and finally the extrusion temperature. Maximizing all three parameters led to the highest tensile properties of the green parts.
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Atomic Diffusion Additive Manufacturing (ADAM) is a recent layer-wise process patented by Markforged for metals based on material extrusion. ADAM can be classified as an indirect additive manufacturing process in which a filament of metal powder encased in a plastic binder is used. After the fabrication of a green part, the plastic binder is removed by the post-treatments of washing and sintering (frittage). The aim of this work is to provide a preliminary characterisation of the ADAM process using Markforged Metal X, the unique system currently available on the market. Particularly, the density of printed 17-4 PH material is investigated, varying the layer thickness and the sample size. The dimensional accuracy of the ADAM process is evaluated using the ISO IT grades of a reference artefact. Due to the deposition strategy, the final density of the material results in being strongly dependent on the layer thickness and the size of the sample. The density of the material is low if compared to the material processed by powder bed AM processes. The superficial roughness is strongly dependent upon the layer thickness, but higher than that of other metal additive manufacturing processes because of the use of raw material in the filament form. The accuracy of the process achieves the IT13 grade that is comparable to that of traditional processes for the production of semi-finished metal parts.