| description abstract | This paper delves into the potential of additive manufacturing (AM) technologies, focusing on the utilization of laser powder bed fusion (LPBF) to optimize the manufacturing process for Mar-M-509, a cobalt-based superalloy, in aeroderivative industrial gas turbine nozzle guide vanes. While Mar-M-509 offers exceptional properties for high-temperature applications, the rapid cooling rates inherent in LPBF introduce significant residual stresses, leading to poor success rates below 50%. The study systematically addresses this challenge by proposing a comprehensive methodology to optimize LPBF parameters. By fine-tuning processing conditions, including elevating the powder bed and build chamber temperatures, the research achieved notable reductions in residual stresses by up to 55%. Computational simulations played a pivotal role in predicting deformations and thermal signatures, enabling proactive adjustments to process conditions, ultimately enhancing part quality and process reliability. Validation through successful printing with a yield exceeding 75% underscores the effectiveness of this approach. Moreover, the study suggests the broader applicability of these optimization strategies beyond Mar-M-509, paving the way for advancements in AM techniques across diverse materials and industrial sectors. This research not only presents a robust solution for mitigating residual stresses in LPBF-produced components but also showcases a proactive methodology that promises significant implications for additive manufacturing's future advancements and applicability. | |
