Tailoring the microstructure of Fe-2.9wt.%Si alloy in laser powder bed fusion using in-source beam shaping

Tuning the irradiance profile of the laser beam opens up new possibilities in terms of controlling the thermal field the material is subjected to during laser powder bed fusion (PBF-LB/M). This control can be exploited to manipulate the material’s microstructure. In this work, a contemporary high power fibre laser with in-source beam shaping capability was used to test different irradiance profiles ranging from Gaussian to ring during the PBF-LB/M of Fe-2.9wt.%Si alloy. This soft magnetic alloy is used in electrical machines, and its magnetic properties are known to be correlated to the microstructure. Initially, the experimental work assessed the influence of peak and ring irradiance levels on densification and grain morphology. In a second experimental run, the influence of the beam profile on the conventionally employed energy density was verified. The results demonstrated that the use of combined Gaussian-ring profiles offers a method for manipulating grain size and shape from a columnar towards an equiaxed shape, without requiring a change in the scan strategy.