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Machining evaluations of 2507 super duplex stainless steel fabricated by laser powder bed fusion
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DOI：10.1007/s40964-026-01904-4.png)
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Abstract
En 中文
Laser powder bed fusion (LPBF), sometimes known as selective laser melting (SLM), is well known used to fabricate super duplex stainless steel (SDSS) components complex structural design. The quick solidification features of LPBF may cause to ferrite-dominant microstructures increased hardness, potentially affect machinability. This work investigates the milling behaviour of LPBF-fabricated SDSS 2507 by comparing the heat response in the cutting zone, surface roughness, chip properties, and near-surface hardness with machining parameters. Nine samples with different cutting conditions (S1–S9) were assessed with spindle speeds ranging from 3000–5000 rpm, feed rates between 50–150 mm/rev, and depths of cut varying from 0.9–1.3 mm. The cutting temperature followed a transient rise–peak–cooling profile and increased with machining aggressiveness, with peak values approaching ~ 300 °C at 5000 rpm (S3/S6/S9), ranging from ~ 128.3 to 298.5 °C. The surface finish was quite dependent on the parameters where the lowest roughness was at S2 (4000 rpm, 50 mm/rev, 0.9 mm), which gave Ra ≈ 0.43 µm, and the maximum roughness was at S9 (5000 rpm, 150 mm/rev, 1.3 mm), which gave Ra ≈ 1.46 µm. Hardness improved as cutting severity increased, suggesting that higher thermo-mechanical deformation led to improved surface work hardening. The more chip discoloration and surface browning suggested that the thermal–mechanical integration was stronger. SEM showed that increasing cutting parameters exacerbated plastic deformation and shear localization, resulting in progressive chip fragmentation and loss of surface integrity. In general, moderate cutting settings provide the optimum between thermal stress and surface integrity.
Keywords:
Selective laser melting
Super duplex stainless steel
Machinability
Cutting temperature
Surface roughness
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