Assessment of Cold Plasma Nitriding Post-processing for Defect Mitigation and Property Optimization of LPBF Martensitic Stainless Steel

Document Type

Conference Proceeding

Publication Date

Summer 7-2026

Abstract

Additive Manufacturing (AM) has transformed the production of complex metal components in aerospace, automotive, and biomedical sectors by enabling lightweight, customized parts with minimal material waste. However, AM processes, particularly laser powder bed fusion (LPBF), are prone to defects such as porosity, residual stresses, high surface roughness, and microstructural inconsistencies that can compromise mechanical performance. Post-processing is therefore critical for achieving the surface quality and reliability required in service. This study presents an experimental investigation of cold plasma nitriding as a post-processing route to mitigate these defects in LPBF-fabricated martensitic stainless steel. Plasma treatment markedly affected the parts, reducing surface microhardness from ≈ 800 HV to ≈ 400 HV and concurrently increasing the friction coefficient (≈ 0.30 → 0.44) and wear rate (1 × 10−6 → ~5 × 10−5 mm3 N−1 m−1). The decrease in hardness indicates residual-stress relief, while the rise in friction and wear suggests that further optimization is needed to balance hardness and durability. Additional plasma-processing experiments and detailed layer analyses are recommended to refine LPBF part properties. By reducing defect-related scrap and rework, the proposed post-processing strategy directly supports sustainable manufacturing goals, lowering material waste and resource consumption across the LPBF production cycle.

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