Fabrication and microstructure characterization of selective laser‐melted FeAl intermetallic parts

Selective laser melting was considered in this study with the goal to manufacture dense parts with mechanical properties comparable to those of bulk materials, directly from FeAl intermetallic powder. Based on a series of single line scans, the processing window was first explored, paying attention to the melting mechanisms. Then, FeAl samples were produced using various selected parameters according to the previously established processing map. These samples were investigated in terms of microstructure, surface roughness, densification and microhardness. Observations revealed that these characteristics are strongly dependent on the processing parameters. Finally, interesting FeAl specimens with a relatively high density (98% of the theoretical value), high microhardness and smooth surface were obtained using a laser power of 90 W and a scanning speed of 0.2 m/s, corresponding to a continuous melting mechanism of the powder bed.