article · Journal of Materials Research and Technology
This study examines the optimisation of selective laser melting parameters to fabricate high-quality components from the nickel-based superalloy Inconel 625. Researchers evaluated how laser power, scan speed, and hatch distance influence the microhardness and surface roughness of printed parts. Characterisation of the spherical powder and manufactured surfaces was conducted using scanning electron microscopy and X-ray diffraction. Laser power emerged as the primary factor governing both microhardness and surface finish, followed by scan speed and hatch distance. Using the Taguchi method, an optimal configuration achieved a microhardness of 416 HV and a surface roughness of 2.82 micrometres. To simultaneously balance both properties, a super ranking concept approach identified a unified operational setting yielding a microhardness of 382 HV and a surface roughness of 3.92 micrometres, which was validated through microscopic surface analysis.
Producing high-performance metal components using additive manufacturing requires precise control over machine settings to prevent defects. By determining exact processing parameters for Inconel 625, this work demonstrates how to systematically achieve high surface smoothness and material hardness without extensive trial and error, supporting the reliable 3D printing of complex superalloy parts.
This research provides applied and experimentally validated processing settings for manufacturers utilizing selective laser melting to print Inconel 625 components. By defining precise operating conditions, the work can assist additive manufacturing technicians and industrial users in reducing component defects and surface finishing needs, representing an applied stage of process optimisation ready for operational benchmarking in 3D printing environments.
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In the current study, near net-shaped selective laser melting (SLM) technology was employed to build nickel-based superalloy Inconel 625 (IN625) parts with good quality. Taguchi method was employed to formulate a systematical study, analyze, and optimize the influencing factors, i.e., laser power (LP), scan speed (SS) and hatch distance (HD) on the resulting micro-hardness (MH) and surface roughness (SR) of the build samples. Scanning electron microscope (SEM) and X-ray diffraction analysis were carried out to characterize the powder morphology (spherical shaped particle possessing the size of 35 ± 6 μm) and the surface of the build samples. Laser power was the most contributing factor on the analyzed parameters (MH and SR), followed by the scanning speed and hatch distance. Taguchi determined optimal condition (MH: LP = 270 W, SS = 800 mm/s, HD = 0.08 mm; SR: LP = 270 W, SS = 800 mm/s, HD = 0.08 mm) which resulted in higher microhardness of 416 HV and lower surface roughness of 2.82 μm. Higher MH was attributed to the minimal porosity, while the uniform smooth surface of the build samples resulted in low SR as evident from the SEM images and surface texture analysis. Super ranking concept (SRC) was used to optimize the MH and SR simultaneously, by determining a single optimal condition (LP = 300 W, SS = 600 mm/s, HD = 0.10 mm). The obtained optimal condition resulted in a MH of 382 HV, and a SR of 3.92 μm. The results of optimal conditions are validated subjected to SEM morphologies.
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DOI: 10.1016/j.jmrt.2021.07.144
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