Influence of phase transformation coefficient on thermomechanical modeling of laser powder bed fusion for maraging 300 steel

Abstract

Manufacturing maraging steel components using laser-based powder bed fusion (LPBF) presents an attractive proposition for industries due to the material's combination of mechanical properties such as hardness, wear resistance, toughness and the capability to produce parts with complex geometries and high precision. Despite these advantages, the LPBF process induces defects such as distortion and residual stress associated with the complex thermal cycles, compromising final part quality. Numerical simulations have been developed to predict these defects. However, LPBF simulations remain challenging due to the complexity of the process and the substantial computational resources required. For maraging steel, for example, the occurrence of phase transformation promotes compressive stress that interferes in results and makes simulations inaccurate. This research aims to simulate a geometry with a circular inner channel and investigate distortion, volume fraction of martensite and equivalent stress results. Modeling was performed by varying phase transformation rate parameters to assess the impact of transformations on simulation outcomes. Results showed minimal impact of these parameters on distortions and equivalent stress. Equivalent stress results were compared with literature findings, while distortion results were validated against experimental data to validate the accuracy of the model.

Keywords

• Laser powder bed fusion (LPBF)
• Numerical simulation
• Additive manufacturing (AM)
• Maraging 300 steel (MS300)
• Phase transformation