Laser-Powder Bed Fusion Additive Manufacturing of NiCrBSi Self-Fluxing Nickel Alloy, Material Health - Process Relationship

Laser Powder Bed Fusion (L-PBF) might be a promising solution for producing complex wear-resistant parts from NiCrBSi self-fluxing nickel alloys. This study investigates a large set of parameters with a baseplate heated up to 500 °C. Furthermore, laser remelting is also explored to further increase surface density and reduce cracking. Material health is deeply investigated by image analysis to quantify different defects (lack of fusion, porosity and cracks). Spatters likely induce lacks of fusion, while the low toughness and high hardness values cause cracks. The lack of fusion surface fraction and crack length decrease with the preheating temperature while the crack width increases. A surface density of 99 % is obtained with careful process optimisation leading to a laser power of 100 W, a laser speed of 750 mm.s -1 and a preheating temperature of 500 °C.