Optimization of Process Parameters for Manufacturing SS316L Parts by LPBF Using a Laser-Adapted Powder Deposition System

This study aims to optimize the process parameters for manufacturing stainless steel AISI 316L (SS316L) components using Laser Powder Bed Fusion (LPBF) with a Laser-Adapted Powder Deposition System. The influence of volumetric energy density (VED), laser intensity, and interaction time on the topography, defect formation, and hardness of the manufactured parts was investigated. The LPBF process parameters were systematically varied, including laser power (50–250 W) and scanning speed (15–250 mm/s). This resulted in VED values ranging from 55.6 to 647.5 J/mm3. The optimization process revealed ideal process conditions at VED values of 170.9, 256.4, and 641.0 J/mm3, with a minimum laser intensity of 11.8 kW/mm2 and interaction times ranging from 0.36 to 2.70 ms. Microstructural analysis revealed a predominantly austenitic phase with residual stresses associated with the LPBF process’s high cooling rates. Mechanical testing showed that parts manufactured under optimized conditions exhibited superior hardness (234–244 HV) compared to conventionally processed SS316L (170–220 HV). It was demonstrated that the laser-adapted powder deposition system can effectively fabricate high-precision components by understanding the interdependencies of parameters in LPBF. This approach contributes to optimizing manufacturing strategies for SS316L components.