Bragg edge Strain Mapping for Characterization of the Performance Enhancement of Additively Manufactured Dievar Gear Teeth by Laser Shock Processing

Additive Manufacturing (AM), particularly Laser-Driven Directed Energy Deposition (DED-LB), offers an efficient method for manufacturing, refurbishing, and recycling metallic components, thereby reducing their environmental impact. DED-LB has been used to fabricate gear teeth from Dievar tool steel, a tough and thermally resistant alloy. Despite its advantages, microcracks at the gear tooth root can affect structural integrity and safety. Laser Shock Processing (LSP) is a promising technique to address this issue by introducing compressive residual stress fields through high-intensity laser-induced shock waves. This enhances fatigue life and prevents crack propagation in high-strength metals. This study compares the residual stresses and mechanical behaviour of additively manufactured and machined Dievar gear teeth, with and without LSP treatment, alongside analysis of related microstructural changes. Bragg edge imaging on the IMAT beamline will be used to provide full-field, near-surface 2D strain maps. This approach remains unexplored for LSP-treated, AM-manufactured gear teeth and offers novel insights.