Densification and microstructural evaluation during laser sintering of M2 high speed steel powder

Abstract In the present work, the densification and microstructure of M2 high speed steel powder processed by direct laser sintering method was studied. Test specimens were produced using a 200 W continuous wave CO2 laser beam at different scan rates ranging from 50 to 175 mm s−1. The building process was performed under argon and nitrogen atmospheres in order to evaluate the role of sintering atmosphere. It was found that the sintered density strongly depends on the laser scan rate and thus on the duration time of the laser beam on the surface of the powder particles. Generally, with a decrease in the scan rate higher densification was obtained. However, formation of large cracks and delamination of the sintered layers is feasible at low scan rates. The results also demonstrated that sintering under argon atmosphere yields better densification compared to a nitrogen atmosphere, in particular at higher scan rates. The microstructure of laser sintered parts consisted of large and elongated pores parallel to the building direction. The metal matrix structure was found to be heterogeneous, i.e. carbon rich austenite was formed due to carbon segregation. This structure consisted of fine cellulars or dendrites of martensite and retained austenite. This article describes the influence of manufacturing parameters on the densification of laser sintered M2 high speed steel powder. The microstructural features of the processed parts are also addressed.