Residual Stress Optimization for Manufacturing of a Nozzle Guide Vane in Mar-M-509 by Laser Powder Bed Fusion

Abstract This paper delves into the potential of additive manufacturing (AM) technologies, focusing on the utilization of laser powder bed fusion (LPBF) to optimize the manufacturing process for Mar-M-509, a cobalt-based superalloy, in aeroderivative industrial gas turbine nozzle guide vanes. While Mar-M-509 offers exceptional properties for high-temperature applications, the rapid cooling rates inherent in LPBF introduce significant residual stresses, leading to poor success rates below 50%. The study systematically addresses this challenge by proposing a comprehensive methodology to optimize LPBF parameters. By fine-tuning processing conditions, including elevating the powder bed and build chamber temperatures, the research achieved notable reductions in residual stresses by up to 55%. Computational simulations played a pivotal role in predicting deformations and thermal signatures, enabling proactive adjustments to process conditions, ultimately enhancing part quality and process reliability. Validation through successful printing with a yield exceeding 75% underscores the effectiveness of this approach. Moreover, the study suggests the broader applicability of these optimization strategies beyond Mar-M-509, paving the way for advancements in AM techniques across diverse materials and industrial sectors. This research not only presents a robust solution for mitigating residual stresses in LPBF-produced components but also showcases a proactive methodology that promises significant implications for additive manufacturing's future advancements and applicability.