Abstract:
To address the high number of layers and limited efficiency associated with the commonly used small layer thickness (20-40 μm) in Selective Laser Melting (SLM) of GH3536 alloy, this study designed and validated an efficient processing parameter window for GH3536 alloy using an 80 μm powder layer thickness. A total of 16 parameter sets (T1–T16) were established by varying the hatch spacing (0.11/0.12 mm), laser power (400/430/450 W), and scanning speed (950-1250 mm∙s⁻¹). Two post-heat treatment conditions, namely solution treatment and hot isostatic pressing plus solution treatment, were applied. The phase constitution, microstructure, and mechanical properties were evaluated using SEM, EDS, XRD, micro-Vickers hardness testing, and room-temperature tensile testing. The results indicate that after solution treatment, melt pool boundaries disappear, and recrystallization-related microstructural features emerge, with porosity reduced compared to the as-built condition. As the scanning speed increases, the grain structure gradually refines, exhibiting a heterogeneous "small grains associated with large grain surfaces" characteristic; precipitates transition from a granular to a linear morphology. The elongation after fracture remains stable around 50%, while yield strength, ultimate tensile strength, and microhardness show a slight increase. With increasing laser power, the grains gradually coarsen, precipitates show minimal change, and elongation after fracture remains stable at approximately 50%; however, yield strength, ultimate tensile strength, and microhardness exhibit a slight decrease. The fracture mechanism of the specimens is primarily a complex mixed mode involving intergranular fracture with dimples present. Within the conditions of this study, the optimal printing parameters identified are: layer thickness of 80 μm, hatch spacing of 0.12 mm, laser power of 430 W, and scanning speed of 1150 mm∙s⁻¹