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In this paper, single-layer and bulk 316 L selective laser melting (SLM) experiments were conducted, fine submicron-scale geometric symmetrical cellular (hexagonal, pentagonal and square), elongated cellular and bands solidification morphologies were found in the laser-melt top surface. Meanwhile, morphological developed sub-grain patterns with quasi-hexagonal cellular, elongated cellular and bands structures (size ~1 μm) coexisting inside one single macro-solidified grain were also identified. This demonstrated the transitions from quasi-hexagonal-cells to elongated cells/bands, and transitions reverse, occurred in the whole bulk under some circumstances during SLM. Based on the experimental realities, these morphologies are formed by the local convection and Bénard instabilities in front of the solid/liquid interface (so-called mushy zones) affected by intricate temperature and surface tension gradients. Quasi-hexagonal cellular convective fields are then superimposed on macro-grain solidification to form the sub-grain patterns and micro-segregations. This explanation seems reasonable and is unifying as it can be expanded to other eutectic alloys with face center cubic (FCC) prevenient phase prepared by SLM, e.g., the Al-Si and Co-Cr-Mo systems.

Morphological Development of Sub-Grain Cellular/Bands Microstructures in Selective Laser Melting