Relationship between microstructure, mechanical and magnetic properties of pure iron produced by laser powder bed fusion (L-PBF) in the as-built and stress relieved conditions

In the present work, the mechanical and magnetic properties of pure iron manufactured by laser-powder bed fusion (L-PBF) were investigated both in the as-built (AB) and stress relieved (HT) conditions, with the aim of elucidating their relationship with the microstructure and evaluating whether and to what extent it can be suitable for industrial applications. The L-PBF process was optimized to obtain high density, crack-free components. Specimens for microstructural analyses, tensile and magnetic tests were manufactured under the optimized conditions and tested both in the as-built and annealed (850 degrees C for 1 h, to relieve the residual stresses) conditions. Tensile tests showed high tensile strength in both AB and HT conditions (larger than those of conventionally produced pure iron), with higher ductility and lower strength after stress relieving. The magnetic study indicated a not optimal magnetic softness although the heat treatment enhanced the permeability and reduced the coercivity with respect to the as-built condition. The high mechanical strength and low magnetic softness came from the very fine grain size (about 5 mu m) of L-PBF pure iron. Instead, the improvement of magnetic softness and ductility after heat treatment was attributed to the possible reduction of dislocation density and consequent stress relief. The results indicated the possibility to achieve a considerably high mechanical strength, in pure iron manufactured by L-PBF, although the fine grain size limits its magnetic softness.