Journal Article

Rapid-Optimized Process Parameters of 1080 Carbon Steel Additively Manufactured via Laser Powder Bed Fusion on High-Throughput Mechanical Property Testing

Feng, Jianyu, Huang, Ke, Wu, Xudong, Huang, Guoliang, Jiang, Meiling

2025

Overview

To ensure the sustainability of alloy-based strategies, both compositional design and processing routes must be simplified. Metal additive manufacturing (AM), with its exceptionally rapid, non-equilibrium solidification, offers a unique platform to produce tailored microstructures in simple alloys that deliver superior mechanical properties. In this study, we employ laser powder bed fusion (LPBF) to fabricate 1080 plain carbon steel, a binary alloy comprising only iron and carbon. Deviating from conventional process optimization focusing primarily on density, we optimize LPBF parameters for mechanical performance. We systematically varied key parameters (laser power and scan speed) to produce batches of tensile specimens, which were then evaluated on a high-throughput mechanical testing platform (HTP). Using response surface methodology (RSM), we developed predictive models correlating these parameters with yield strength (YS) and elongation. The RSM models identified optimal and suboptimal parameter sets. Specimens printed under the predicted optimal conditions achieved YS of 1543.5 MPa and elongation of 7.58%, closely matching RSM predictions (1595.3 MPa and 8.32%) with deviations of −3.25% and −8.89% for YS and elongation, respectively, thus validating model accuracy. Comprehensive microstructural characterization, including metallographic analysis and fracture surface examination, revealed the microstructural origins of performance differences and the underlying strengthening mechanisms. This methodology enables rapid evaluation and optimization of LPBF parameters for 1080 carbon steel and can be generalized as an efficient framework for robust LPBF process development.

• Publisher: MDPI AG,MDPI
• Subject: 3D printing / Additive manufacturing / Alloys / Automation / Binary alloys / Carbon steel / Carbon steels / Crack propagation / Ductility / Elongation / Environmental sustainability / Experimental methods / Fracture surfaces / Friction stir welding / Grain size / Lasers / Mechanical properties / Mechanical tests / Metal fatigue / Microstructure / Morphology / Optimization / Parameter identification / Powder beds / Powders / Prediction models / Process controls / Process parameters / Research methodology / Response surface methodology / Software / Solidification / Thermal cycling / Wear resistance / Yield strength / Yield stress