Effects of heat treatment on the microstructure, residual stress, and mechanical properties of Co–Cr alloy fabricated by selective laser melting

The mechanical properties and residual stress of dental Co–Cr–Mo (CCM) alloy depend on the manufacturing and post-processing methods, which affect the prognosis of dental prostheses. Two CCM alloys manufactured by casting and selective laser melting (SLM) were compared, and the effect of heat treatment temperature for CCM alloys manufactured by SLM method was evaluated. Specimens were fabricated by casting (Cast Co–Cr) and SLM (SLM Co–Cr). SLM Co–Cr specimens were heat treated at 750, 950, and 1150 °C to compare their properties. Microstructures were analyzed via scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), and electron backscattered diffraction (EBSD), and the residual stress was measured via x-ray diffraction (XRD). Mechanical properties were evaluated by a Vickers hardness test and a tensile test; fractography was performed after this. The SLM Co–Cr group exhibited a decrease in porosity, grain size, increase in solid solution limit, and high residual stress compared to Cast Co–Cr; the ultimate tensile strength, yield strength, and hardness were also higher. The microstructures, residual stresses, and mechanical properties differed significantly depending on the heat treatment, and the strength and hardness showed a tendency inverse to that of the elongation. Type I residual stresses mostly decreased after 750 °C heat treatment, however type II and III residual stresses remained even after 1150 °C heat treatment. SLM presented superior mechanical properties to casting. Considering the reduction of tensile residual stress and increased ductility, CCM alloys should be heat treated at a temperature of 950 °C or higher. [Display omitted] •SLM Co-Cr was less porous and had better mechanical properties than Cast Co-Cr.•HCP phase dominated FCC phase in SLM Co-Cr heat treated but only at 750 °C.•Increasing heat treatment temperature improved the ductility of SLM Co-Cr.•Type I residual stress was reduced by heat treatment, unlike types II and III.