Characterization of an iron-based laser sintered material

Direct Metal Laser Sintering (DMLS) is a relatively new rapid tooling technique to fabricate near net-shaped parts. Properties of DMLS parts are governed by their microstructure. Hence, characterization of microstructure is of significant importance. In this study, a new iron-based DMLS material was characterized to unveil its metallic microstructure to support the prediction of end-user performance and the development of new applications. Characteristics of powder particles, roughness and topography of sintered surfaces, and microstructure of sintered body were investigated. The original powder composition, the particle size, particle morphology and processing parameters were discussed relative to the sintered phases, the porosity and the microstructure. We found a microstructural waviness existing in the DMLS material. Some possible reasons are discussed.