Impact of Post-Processing on Residual Stress Development of Binder Jetting Components

The growing demand for sustainability and process optimization is driving significant advancements in materials, design methodologies, and manufacturing technologies. Binder Jetting (BJT) is a promising additive manufacturing technique that offers substantial design freedom and high productivity. However, BJT-produced parts often exhibit performance limitations compared to wrought steel due to surface integrity characteristics such as porosity and roughness. While residual stress profiles are known to significantly influence the fatigue performance of wrought steel, their impact on BJT components remains insufficiently explored. This study examines the effects of various manufacturing processes on 17-4PH samples produced via BJT, comparing them to conventionally manufactured counterparts. The investigation includes turning, aging, and shot peening. Residual stress evolution is assessed throughout the manufacturing chain to verify the impact of each manufacturing stage on the final stress state. Results indicate that sintering produces a neutral residual stress profile. Shot peening before aging creates a densified layer with minimal impact on residual stresses, whereas peening after aging induces a compressive stress profile comparable to wrought steel. Combining turning for geometric accuracy, shot peening before aging for densification, and final shot penning for compressive residual stress induction is crucial for enhancing the fatigue performance of Binder Jetting parts.