Surface analysis and mechanical properties of stainless steel 316L toothed wheel manufactured by powder bed fusion

• Published in: International journal of advanced manufacturing technology Vol. 137; no. 5; pp. 2889 - 2898
• Main Authors: Ashkani, Omid, Rezayat, Mohammad, Fathi, Sina, Sadeq, Abdellatif M., Mehrabi, Hamid, Armstrong, Mark
• Format: Journal Article
• Language: English
• Published: London Springer London 01.03.2025; Springer Nature B.V
• Subjects: Advanced manufacturing technologies; Austenitic stainless steels; CAE) and Design; Computer-Aided Engineering (CAD; Corrosion resistance; Diamond pyramid hardness; Engineering; Industrial and Production Engineering; Mechanical Engineering; Mechanical properties; Media Management; Near net shaping; Original Article; Powder beds; Process parameters; Residual stress; Sigma phase; Stainless steel; Surface analysis (chemical); Surface roughness; Tensile strength; Powder bed fusion (PBF); Additive manufacturing; 316L stainless steel; 3D printing
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-025-15364-7

This study examines the fabrication of toothed wheels from 316L stainless steel using powder bed fusion (PBF), evaluating surface roughness, dimensional fidelity, and mechanical performance in the as-built condition. Results reveal near-net shape (NNS) accuracy, within ± 0.05 mm of the intended geometry, and a tensile strength of 720 MPa, exceeding many traditional manufacturing processes. The rapid cooling characteristic of PBF induces a refined, nearly pore-free microstructure, driving Vickers hardness values up to 244.5 HV. Although no post-processing was used, average surface roughness remained at a modest 27.5 µm (ISO 1302 N11), emphasizing PBF’s ability to fabricate complex features without compromising the overall finish. Thermodynamic simulations illustrate that secondary carbide formation and internal stresses contribute to the alloy’s improved strength, though the emergence of the sigma phase could locally reduce corrosion resistance. These findings emphasize the potential of PBF to deliver both dimensional precision and mechanical robustness in components subject to high-load, high-precision applications. Looking ahead, expanding the range of materials and refining process parameters, including laser power and scanning speed, offer promising directions for further performance gains and broader industrial adoption.