Effects of heat treatment and geometry on mechanical properties and precipitate development in martensitic additively manufactured 17-4 PH

Reliable mechanical properties of precipitation strengthened alloys like 17-4 PH stainless steel are conventionally obtained through tightly controlled thermomechanical processing to optimize the size and distribution of strengthening precipitates. In additive manufacturing, however, the thermal history (e.g. heating and cooling rates) can vary significantly across a part or individual layer causing the precipitate distribution and resulting mechanical properties to be non-uniform. This is especially true for precipitation strengthened alloys like 17-4 PH which require a specific thermal history to achieve the expected phases and properties. To explore this material and the effect that standard heat treatments have on the processing-structure-properties relationship for AM 17-4 PH, a series of thin-wall (0.8 mm) and ASTM E8 size dogbones were printed via SLM and tensile tested in the as-built, solution annealed, and H900 condition. A Vic-2D DIC system was used during tensile testing to obtain full-field strain data. SEM BSE imaging and TEM EDS were used to characterize the larger (60–120 nm) precipitate phases (SiO and NbC) along with the overall microstructure. GISAXS and TEM EDS were used to quantify the size (5–15 nm), shape, distribution, and composition of nanoscale copper-rich precipitates. Overall, the mechanical properties between the E8 and thin-wall samples were similar with yield strengths of 677 and 734 MPa and ultimate strengths of 1049 and 941 MPa in the H900 condition, respectively. The other sample conditions follow similar trends with the only significant difference being a drop in average ductility (0.27 vs 0.17) for the thin-wall geometry. These similarities were hypothesized to stem from several factors which work to lessen the cooling rate dependence of 17-4 PH.