Residual Stresses Measurements in Laser Powder Bed Fusion Using Barkhausen Noise Analysis

Area of Science:

• Materials Science
• Additive Manufacturing
• Non-destructive Testing

Background:

• Laser powder bed fusion (LPBF) is advancing industrially, but residual stresses remain a challenge.
• Maraging steel 300 (18Ni-300/1.2709) is a key material in LPBF applications.
• In situ monitoring of residual stresses is crucial for quality control.

Purpose of the Study:

• To evaluate Barkhausen noise analysis (BNA) for in situ residual stress monitoring in LPBF of Maraging steel 300.
• To validate BNA's principle and assess its applicability for residual stress variations.

Main Methods:

• Microstructure characterization, including grain size distribution, was performed.
• Experiments involved an external force setup to validate BNA principles.
• On-plate samples with varying residual stress states were analyzed using BNA.

Main Results:

• Consistent microstructure stability was observed, supporting BNA prerequisites.
• External load tests confirmed signal variation correlates with induced stress.
• On-plate BNA measurements showed signal variations consistent with literature for residual stress changes.

Conclusions:

• Barkhausen noise analysis is suitable for qualitative monitoring of residual stress variations during LPBF.
• BNA is a promising candidate for in situ residual stress measurement in additive manufacturing.