Cui, Chengsong, Felix Stern, Nils Ellendt, Volker Uhlenwinkel, Matthias Steinbacher, Jochen Tenkamp, Frank Walther, and Rainer Fechte-Heinen.
Materials. 2023; 16(1):435.
Duplex stainless steel powders for laser additive manufacturing have not been developed extensively. In this study, the melts of a super duplex stainless steel X2CrNiMoCuWN25-7-4 (AISI F55, 1.4501) were atomized with different process gases (Ar or N2) at different atomization gas temperatures. The process gas N2 in the melting chamber leads to a higher nitrogen dissolution in the steel and a higher nitrogen content of the atomized powders. The argon-atomized powders have more gas porosity inside the particles than the nitrogen-atomized powders. In addition, the higher the atomization gas temperature, the finer the powder particles. The duplex stainless steel powders showed good processability during PBF-LB/M (Laser powder bed fusion). The gas entrapment in the powder particles, regardless of the gas chemistry and the gas content, appears to have a negligible effect on the porosity of the as-built parts.