A novel multiscale process simulation to predict the impact of intrinsic heat treatment on local microstructure gradients and bulk hardness of AISI 4140 manufactured by laser powder bed fusion

ABSTRACT

Although finite element model based process simulations for the laser powder bed fusion additive manufacturing process have become more common in the recent years, the proposed approaches are often only viable for materials without complex phase transformations. Process simulations for materials such as the quench and tempering steel AISI 4140 typically lead to higher computational cost due to the finer mesh and time steps needed for more complex material models. This study proposes a novel multiscale approach to combine the advantages of the macroscale and mesoscale models into one framework, in order to reduce computational cost while retaining the high accuracy. The implementation of these multiscale methods was validated by experimentally analyzing multiple parameter combinations regarding bulk hardness and local microstructure differences. The results show an accurate prediction of bulk hardness and localised tempering effects while reducing the computational cost in order to simulate the component scale.

KEYWORDS:

• Laser powder bed fusion
• additive manufacturing
• quench and tempering steel
• multiscale finite element simulation
• hardness

Acknowledgments

The authors thank Gregor Graf and Philipp Schwarz from Rosswag Engineering GmbH for manufacturing the samples used in this study. This research did not receive any specific grant from funding agencies in the public, commercial, or not-for-profit sectors. We acknowledge support by the KIT-Publication Fund of the Karlsruhe Institute of Technology.

Disclosure statement

No potential conflict of interest was reported by the author(s).