Laser powder bed fusion of oxide dispersion strengthened FeCrAl alloy: Processing and microstructural evolution.

Optimizing and regulating the process parameters to form a uniform distribution of nanosized dispersoids remains a major challenge in additive manufacturing oxide dispersion strengthened (ODS) alloys. This study introduces the influence of scanning speed and laser power on the microstructure evolution of laser powder bed fusion (LPBF) ODS FeCrAl alloy. Low laser power and high scanning speed reduce the size of oxide particles and increase their number density. The energy density threshold is 83 J/m3, below which the powder fails to achieve complete melting, leading to the formation of defects during solidification. High density and large number of oxide particles were obtained for the printed samples under the parameters of 140 W laser power and 600 mm/s scanning speed. The average size and number density of oxide particles were ∼ 21.61 nm and ∼ 1.8 × 1020/m3, respectively. High scanning speed have a rapid cooling rate which affects the dislocation density and the average width of the columnar grains. Low laser power significantly weakens the 〈100〉 fiber texture, which is related to the degree of recrystallization in the remelted region. The core-shell oxides consisting of Y-Al-O and Y-Ti-O were distributed in the samples deposited at low and high laser powers, respectively. The formation of core-shell oxide particles in LPBF ODS FeCrAl alloys involves solid-state amorphization and recrystallization. This study can be a guideline to achieve materials with specific microstructure for ODS alloys. • High-density ODS FeCrAl alloys were built by selective laser melting (SLM) process. • Low laser power and high scanning speed result in obtaining small-sized and high-density nanoparticles. • The modification of the laser power affects the composition of core-shell structured oxide particles. • The formation of nanoparticles in SLM ODS FeCrAl alloys involves solid-state amorphization and recrystallization. [ABSTRACT FROM AUTHOR]