Research on Quality Inspection of PBF-LB 022Cr17Ni12Mo2 Steel Using Laser Ultrasonic Testing Technology

In this study, laser powder bed fusion (PBF-LB) 022Cr17Ni12Mo2 steel plates with dimensions of 50 mm × 50 mm × 2 mm were fabricated using a laser power of 206 W, a scanning speed of 900 mm/s, a hatch spacing of 90 μm, a layer thickness of 30 μm, and an interlayer scanning rotation of 67°. The specimens were then subjected to solution treatment at 900–1100 °C for 30 min and at 950 °C for 30–120 min. Unlike previous ultrasonic studies on additively manufactured metals, which mainly focused on defect detection, elastic-constant characterization, or residual stress evaluation, this work investigates whether solution-treatment-induced changes in grain size and dislocation density can be quantitatively reflected by laser-ultrasonic attenuation and further correlated with yield strength. Laser ultrasonic nondestructive testing using a 1064 nm pulsed laser with a pulse width of 8 ns and a pulse energy of 500 mJ was combined with metallographic observation, EBSD characterization, XRD analysis, tensile testing, and microhardness measurement. The results show that the solution-treated samples retained a single-phase γ-austenitic structure, while microstructural recovery, weakening of PBF-LB-induced cellular substructures, and partial annihilation of cell-wall dislocations led to a reduction in KAM-derived dislocation density from 2.04 × 1014 m−2 to 1.45 × 1014 m−2 and a decrease in yield strength from 466.9 MPa to 407.4 MPa. Within the present dataset, the EBSD-equivalent grain size showed an apparent positive correlation with ultrasonic attenuation, while the KAM-derived dislocation density showed an empirical negative correlation with ultrasonic attenuation. However, ultrasonic attenuation should be interpreted as a combined microstructure-sensitive response rather than as a response controlled only by EBSD-equivalent grain size or dislocation density. Based on the empirical correlations among ultrasonic attenuation, EBSD-equivalent grain size, KAM-derived dislocation density, and yield strength, a preliminary attenuation-based calibration model was established for the present solution-treated samples. The model should be regarded as an in-sample empirical calibration within the present experimental range rather than a general Hall–Petch-based predictive model. The model showed good in-sample fitting performance, with (R2) values higher than 0.85 and a maximum in-sample fitting error of 3.85%. However, because the model was established and assessed using the same eight solution-treatment conditions, it should be regarded as a preliminary calibration model within the present experimental range rather than a general predictive model. This study demonstrates the potential of laser ultrasonic attenuation for non-contact evaluation of microstructural and mechanical-property variations in solution-treated PBF-LB 022Cr17Ni12Mo2 steel.