Microstructural evolution and control in laser material processing

Laser processing, because of its characteristic features, often gives rise to unique microstructure and properties not obtained with other conventional processes. We present various diverse laser processing case studies involving control of microstructure through judicious selection of processing parameters carried out with indigenously developed high power CO2 lasers. The first study describes microstructural control during end plug laser welding of PFBR fuel pin, involving crack pone alloy D9 tube and type 316 M stainless steel (SS) plug, through preferential displacement of focused laser beam. Crater and associated cracks were eliminated by suitable laser power ramping. Another case study describes how low heat input characteristics of laser cladding process has been exploited for suppressing dilution in 'Colomony 6' deposits on austenitic SS. The results are in sharp contrast to extensive dilution noticed in Colmony 6 hard faced deposits made by GTAW. A novel laser surface melting (LSM) treatment for type 316 (N) SS weld metal has been developed to generate a sensitization-resistant microstructure which leads to enhanced resistance against intergranular corrosion (IGC). IGC resistance of laser treated surface has been found to be critically dependent on laser processing parameters. Experimental observations have been analyzed with thermal simulation. We have also studied the effect of laser beam spatial intensity profile on the microstructure in LSM. We have developed laser-assisted graded hard facing of austenitic SS substrate with Stellite 6 which, in contrast to direct deposition either by laser or GTAW, produced smooth transition in chemical composition and hardness used to control grain coarsening and martensite formation in type 430 SS weldment. Laser rapid manufacturing (LRM) is emerging as a new rapid and cost effective process for low volume fabrication, esp. of expensive materials. The talk will also present microstructural characteristics of laser rapid manufactured components of type 316 L SS and Colmon 6. (author)