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<p>This research investigates fatigue-related challenges in the selective laser melting (SLM) fabrication of 17-4PH stainless steel traction rods intended for rail transit applications. To reduce process-induced defects, laser energy density (LED) is utilized as a comprehensive parameter integrating various processing conditions, with optimal settings identified through second-order regression analysis. A correlation framework linking processing parameters, microstructure, and material properties is developed using three-dimensional microstructural reconstruction alongside extensive mechanical testing. Under optimized processing conditions (220 W laser power, 800&#xa0;mm/s scanning speed, 0.05&#xa0;mm hatch spacing, and 0.13&#xa0;mm layer thickness), a relative density of 99.6% is attained, accompanied by improvements in tensile strength and fatigue life of 9.2% and 40%, respectively. Microstructural investigations highlight the critical influence of melt pool morphology on defect formation and evolution. An optimal LED range of 40–50&#xa0;J/mm<sup>3</sup> is established, offering quantitative guidance for the additive manufacturing of high-performance, load-bearing components.</p>

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Process Parameter Optimization and Surface Quality–Performance Relationship in Selective Laser Melting of 17-4PH Stainless Steel

  • 期刊论文

  • 发表日期：

    2026年4月27日

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  • Chunzheng Wang,
  • Xinlin Wang,
  • Meichao Qin,
  • Zhiqiang Hu

摘要

This research investigates fatigue-related challenges in the selective laser melting (SLM) fabrication of 17-4PH stainless steel traction rods intended for rail transit applications. To reduce process-induced defects, laser energy density (LED) is utilized as a comprehensive parameter integrating various processing conditions, with optimal settings identified through second-order regression analysis. A correlation framework linking processing parameters, microstructure, and material properties is developed using three-dimensional microstructural reconstruction alongside extensive mechanical testing. Under optimized processing conditions (220 W laser power, 800 mm/s scanning speed, 0.05 mm hatch spacing, and 0.13 mm layer thickness), a relative density of 99.6% is attained, accompanied by improvements in tensile strength and fatigue life of 9.2% and 40%, respectively. Microstructural investigations highlight the critical influence of melt pool morphology on defect formation and evolution. An optimal LED range of 40–50 J/mm3 is established, offering quantitative guidance for the additive manufacturing of high-performance, load-bearing components.