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<p>Recently, significant studies have been reported on the effect of the powder bed fusion-laser beam (PBF-LB) process parameters (such as scanning strategies (SSTs), laser power, infill patterns (IPs), and layer thickness) on thermal gradients, melt pool stability, phase transformation, and mechanical performance. The existing literature has outlined the individual effects of scan paths or geometry on porosity and strength of functional parts fabricated by PBF-LB under tensile and compressive conditions. However, limited understanding exists regarding how specific SSTs and IPs collectively affect flexural properties (strength, stiffness, energy absorption, etc.), thermal behavior, residual stresses, and microstructural evolution in 17-4 precipitation-hardened (PH) stainless-steel (SS) parts for implant/prosthetic applications. This study systematically investigates the combined effect of SSTs (rectangular/island, stripe (alternate scan), and hexagonal (inside-out scan) path) and IPs (solid, Octet, and Weariphelan (WP)) on the performance of 17-4 PH SS components as an extension of tensile and compressive studies. Results demonstrate that the rectangular SST with full-solid geometry delivers a superior index of toughness (3036&#xa0;MPa), energy absorption (22.85&#xa0;MJ/mm<sup>3</sup>), and proof resilience (1907.19&#xa0;MPa) due to uniform cooling and stable melt-pool dynamics (calculated using Island scanning), which also helps to reduce residual stresses. Conversely, IPs (Octet and WP) with interrupted or long scan paths aggravate thermal inconsistencies, higher porosity, and brittle mechanical failure. Thermo-Calc simulations (thermal gradient versus solidification rate (G–R) analysis, phase evolution, and temperature distribution) support these findings.</p>

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Comprehensive Investigation of Scan Strategies and Infill Patterns on the Flexural, Thermal, and Microstructural Behavior of Powder Bed Fusion-Laser Beam-Processed 17-4 PH Stainless Steel

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Ravinder Singh,
  • Rupinder Singh,
  • IPS Ahuja

摘要

Recently, significant studies have been reported on the effect of the powder bed fusion-laser beam (PBF-LB) process parameters (such as scanning strategies (SSTs), laser power, infill patterns (IPs), and layer thickness) on thermal gradients, melt pool stability, phase transformation, and mechanical performance. The existing literature has outlined the individual effects of scan paths or geometry on porosity and strength of functional parts fabricated by PBF-LB under tensile and compressive conditions. However, limited understanding exists regarding how specific SSTs and IPs collectively affect flexural properties (strength, stiffness, energy absorption, etc.), thermal behavior, residual stresses, and microstructural evolution in 17-4 precipitation-hardened (PH) stainless-steel (SS) parts for implant/prosthetic applications. This study systematically investigates the combined effect of SSTs (rectangular/island, stripe (alternate scan), and hexagonal (inside-out scan) path) and IPs (solid, Octet, and Weariphelan (WP)) on the performance of 17-4 PH SS components as an extension of tensile and compressive studies. Results demonstrate that the rectangular SST with full-solid geometry delivers a superior index of toughness (3036 MPa), energy absorption (22.85 MJ/mm3), and proof resilience (1907.19 MPa) due to uniform cooling and stable melt-pool dynamics (calculated using Island scanning), which also helps to reduce residual stresses. Conversely, IPs (Octet and WP) with interrupted or long scan paths aggravate thermal inconsistencies, higher porosity, and brittle mechanical failure. Thermo-Calc simulations (thermal gradient versus solidification rate (G–R) analysis, phase evolution, and temperature distribution) support these findings.