Fixed-Overlap Stripe Narrowing Suppresses Cracking by Shortening the Semisolid Interval in PBF-LB CM247LC

Authors: John F. Stanton 1 , * , jessica Parker 2
1 University of Florida
2 University of Bath
Volume 4 (2025) Issue 1, DOI: https://doi.org/ 10.71448/jcm2025v4i12
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Abstract

In PBF-LB, CM247LC exhibits excellent \gprime{} precipitation but is prone to severe sensitivity to segregation-induced liquid separation, grain-boundary cracking at large angles, and build-direction residual stress. This work presents a study of the stripe-width transition achieved using 0.12 mm stripe overlap, constant laser power, scan speed, hatch spacing, layer thickness, skywriting, and 67\textdegree{} interlayer rotation. The study centers on the metallurgical issue of whether the low-crack condition at 0.2 mm arises simply because of less penetration or a consequence of overlap-dominated reduction of the risky semisolid regime. The six stripe widths of 5, 2.5, 1, 0.7, 0.5, and 0.2 mm are compared based on the observations of crack density, melt pool depth, build-direction residual stress, ECCI dislocation density, EBSD texture, boundary fraction, APT boundary chemistry, and simulated mushy zone length. Four parameters are calculated: overlap fraction, semisolid compactness, crack burden, and stress-normalized cracking. The analysis separates the stripe range into three different regimes. At 5 mm stripe width, the cracking is moderate at 0.62 mm mm$^{-2}$, while the build-direction residual stress is quite high at 842 MPa. At 1 mm stripe width, the combination of parameters is worst, with the largest mushy zone length of 1.06 mm, highest crack density of 1.71 mm mm$^{-2}$, and residual stress value of 690 MPa that is regarded as a damage-relieved one. At 0.2 mm stripe width, the overlap fraction equals 0.600, compactness 0.131, crack burden 0.096, stress-normalized cracking 0.446, and build-direction residual stress 647 MPa. Thus, the conclusion is quite specific: crack resistance at 0.2 mm is a combined effect of remelting with a fixed overlap, compactness of the semisolid regime, ⟨100⟩ orientation in the build direction, and stress integrity.

Keywords

CM247LC,powder bed fusion-laser beam,stripe width,fixed overlap,mushy zone,solidification cracking,residual stress,atom probe tomography

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