This study investigates the fracture behavior of 316L stainless steel specimens fabricated via Selective Laser Melting (SLM) using varying energy densities. The impact of energy density on fracture characteristics is assessed through fractographic analysis. Experimental findings reveal that specimens produced at an energy density of 64.94 J/mm3 exhibit enhanced toughness, while those processed at 117.29 J/mm3 demonstrate increased porosity due to excessive energy input, leading to brittle fracture. A representative volume element model is developed to evaluate the effects of microstructural features, specifically melt pool boundaries and grain morphology, on the fracture performance of SLM-fabricated 316L stainless steel. Simulation results indicate that grain size and orientation significantly influence fracture behavior, with finer grains enhancing both fracture toughness and tensile strength more effectively than the melt pool boundary. These insights inform SLM parameter optimization for improved mechanical properties in 316L stainless steel.
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