PSI - Issue 77

Jakob Blankenhagen et al. / Procedia Structural Integrity 77 (2026) 198–206 Author name / Structural Integrity Procedia 00 (2026) 000–000

200

3

® HSA (Blankenhagen et al. (2025)), S460NL,

Table 1. Material properties and chemical composition of the used materials PBF-LB / M / Printdur

and G 18 8 Mn (ESAB (2025)) Material

Yield strength Ultimate tensile Elongation at

Chemical composition

R p0.2 in MPa strength in MPa fracture in % C Si

Mn

Cr

Ni

Mo

N

® HSA 927.0

PBF-LB / M / Printdur S460NL (1.8903) G 18 8 Mn (1.4370)

1153.3

38.1 24.8

0.41 0.24 18.77 18.10 0.14 2.04 0.41 0.18 0.47 1.68 0.03 0.01 0.004 0.03

547.4

687.4

400

590

40

0.10 0.60 6.50 19.00 9.00

-

-

® HSAplates

Table 2. Laser parameters for the manufacturing of the PBF-LB / M / Printdur

Energy density in J / mm²

Scanning velocity in mm / s

Laser power in W Layer thickness in µ m Hatch distance in µ m

65.97

600

190

40

100

Laser welding was performed using a SITEC gantry system equipped with a Trumpf TruDisk 6001 laser. A power of 5.5 kW was applied with an o ff set angle of 2–3°. The Trumpf BrightLine technique was employed, distributing 80 % of the power to the core and 20 % to the shell. The diameter of the spot is thus determined to be 100 µ m in the core and 400 µ m in the shell. Argon served as shielding gas, directed at 60° towards the weld. To stabilize weld initiation and termination, a power ramp from 4.0 kW to 5.5 kW within the first and last 5 mm of the weld was applied. The welding speed was set to 2.0 m / min. MIG welding was conducted using an EWM Phoenix machine with G 18 8 Mn filler. The filler rod had a diameter of 1.0 mm. The weld consisted of two layers, with parameters optimized through preliminary trials. The root pass was welded at 127 A, 20.5 V, and 34.0 cm / min (short-circuit transfer (SCT)), followed by a cover pass at 168 A, 26.2 A, and 34.0 cm / min (SCT). After welding, tensile specimens were extracted from the plates by water-jet cutting, followed by machining to the final geometry according to Fig. 2 (a). This ensured smooth edges to avoid premature failure during testing.

(a)

(b)

5 cm

5 cm

Front

Front

Back

Back

5 cm

5 cm

(c)

(d)

30,00°

30,00°

S460

Printdur HSA

S460

Printdur HSA

2

1

6 mm

6 mm

0.1 mm

1.5 mm

Fig. 1. (a) front and back of laser welded specimen, (b) front and back of MIG welded specimen, (c) specimen preparation for laser welding, (d) specimen preparation for MIG welding

For each welding method, three tensile tests were performed on the dissimilar joints. To further study the heat a ff ected zone (HAZ) of Printdur ® HSA, additional specimens were heat-treated using a Ba¨hr DIL805 A / D dilatometer. A total of 36 specimens were treated at maximum temperatures of 800 °C, 1000 °C, and 1200 °C with t 8 / 5 cooling times of 5 s, 10 s, 15 s, and 20 s. The specimen geometry is shown in Fig. 2 (b). This approach enables the simulation