| Abstract Scope |
Cracking during additive manufacturing (AM) and post-AM processes can negatively impact components, but conventional analytical practices may obscure the true extent of cracking. In many cases, AM alloys and processing conditions can produce seemingly crack-free samples, with cracks only becoming apparent in late research stages or near applications. To investigate the underlying causes, crack-susceptible alloy samples with various geometries were prepared using laser powder bed fusion (LPBF) and analyzed on different cutting planes with diverse metallographic methods. Results show that conventional metallography can sometimes conceal microcracks, resulting in an apparently crack-free microstructure. Additionally, sample geometries and sampling planes significantly influence measured crack density, especially in commonly-used rectangular samples. This study aims to address the challenges and mitigation practices for accurately observing AM alloy sample cracking states, facilitating better component performance and reliability. |