Search Results (176)

This study thoroughly investigates the fatigue behavior and properties of additively manufactured (AM) 18Ni300 maraging steel, crucial for the design of load-carrying engineering components. Thin-walled flat specimens, produced via Selective Laser Melting (SLM), underwent a specific thermal process of annealing and aging. Extensive monotonic and cyclic tests (R = 0.1) were conducted to determine static and fatigue material properties. Optical microscopy revealed the thermal process’s effect on microstructure. Experimentally determined design S-N curves, covering low-cycle to engineering endurance limits, allowed estimation of fundamental elastoplastic properties. This work provides valuable new insights and experimentally verified data, addressing a significant literature gap and supporting advanced fatigue-based design for AM components. Full article

In this article, models for prediction of surface hardness for SLM specimens are presented. In experiments, EOS Maraging Steel MS1 was processed using EOS M 290 3D printer via selective laser melting (SLM). To predict hardness of SLM specimens, several machine learning methods were applied, including genetic programming, neural network, multiple regression, k-nearest neighbors, support vector machine, logistic regression, and random forest. In the research, fractal geometry was used to characterize the complexity of SLM-shaped microstructures. It was found that fractal geometry combined with machine learning techniques together greatly improved our comprehension of the intricacies of surface analysis and provided highly efficient predictions. All the applied algorithms exhibited predictability above 90%, with the best average result of 98.7% for genetic programming. Full article

Maraging steels encounter tremendous aerospace applications, such as in landing gears, rocket motor casing, pressure vessels, satellite launch vehicles, etc. Laser welding is considered one of the most effective manufacturing processes due to its minimal instances of wider heat-affected zones (HAZs), precipitate accumulation, and other benefits. However, it should also be noted that their severe effect is still evident in terms of the tensile strength and fatigue strength of laser-welded maraging steel. This paper provides a critical review of the evolution of microstructural features and mechanical properties of laser-welded maraging steel, including corresponding factors in terms of microstructures and the formation of reverted austenite, as well as precipitation hardening from various studies on maraging steels. We examined the influence of precipitation, reverted austenite, welding, and post-weld heat treatment on mechanical properties like hardness, tensile strength, yield strength, elongation, and fatigue strength of laser-welded maraging steel. It is worth mentioning that the laser welding process is generally insufficient for welding sheets with a thickness over 10 mm or those requiring multi-pass welding. The reheating process becomes unfavorable for maraging steel in the multi-pass welding process since it may induce localized heat treatment. Although hybrid welding may resolve an arising thickness issue, the reversion of austenite and complexity are still difficult to overcome due to the dual nature of welding processes, resulting from the use of both arc and laser. Furthermore, maraging steel produced via additive manufacturing tends to avoid austenite reversion with effective heat treatment prior to any welding process. Post-weld heat treatment and cryogenic treatment have been found to be favorable for desired reverted austenite formation. Finally, the proposed constructive framework specifically applies to the welding process of maraging steel, particularly for aerospace applications. Full article

For L-PBF (Laser Powder Bed Fusion) metal additive manufacturing (AM) the choice of available materials is still limited. 1.2709 maraging steel powders are widely used for injection molds and high-quality engineering parts. The quality of the parts produced by L-PBF are significantly affected by the process parameters. The aim of this research was to find optimal process parameters for producing 1.2709 tool steel at a layer thickness of 20 µm and to reveal the possible parameter settings yielding comparable build quality as the “EOS surface” parameter set at a layer thickness of 20 µm. Findings showed that too low or too high input energies produce improper parts. A large range of parameters produce good quality parts, of which the optimum parameters can be chosen. Full article

Additively manufactured maraging steel components often require surface engineering to achieve superior wear resistance for demanding industrial applications. This study investigates 18Ni300 maraging steel manufactured by Laser Powder Bed Fusion (L-PBF), comparing non-aged and pre-aged (480 °C × 6 h) specimens to systematically analyze the effects of nitriding duration (0 h, 24 h, 48 h, 60 h) on nitride layer microstructure, hardness, and wear resistance. Results show that the non-aged specimen, with its supersaturated solid solution matrix, exhibits slower nitride layer growth; a thin, dense nitride layer formed after 24 h of nitriding minimizes the wear depth (−9.043 μm) for optimal friction reduction. In the pre-aged specimen, matrix refinement, through intermetallic compound precipitation, enables a 211 μm nitride layer to form after 48 h of nitriding, elevating surface hardness to 650 HV, and creating a gradient structure (“high-hardness surface + strengthened matrix”), which yields the narrowest and shallowest wear scars and superior wear resistance. The experiments demonstrate that nitriding processes must align with matrix states; 24 h nitriding suits non-aged steel, while 48 h is optimal for aged steel, providing critical guidance for optimizing surface strengthening in additively manufactured 18Ni300 steel. Full article

The primary objective of this research is to simplify and make the industrial manufacturing process of coated maraging steels more economical by combining the advantages of additive manufacturing with simultaneous bulk (aging) and surface (nitriding) treatment in an effective manner. With this aim, preliminary experiments were performed that demonstrated the hardness (and related microstructure) of an as-built MS1 maraging steel, produced by selective laser melting (SLM), is comparable to that of the bulk maraging steel products treated by conventional solution annealing. The direct aging of the solution-annealed and as-built 3D printed maraging steel resulted in similar hardness, indicating that the kinetics of the precipitation hardening process are identical for the steel in both conditions. This assumption was strengthened by a thermodynamic analysis of the kinetics and determination of the activation energy for precipitation hardening using Differential Scanning Calorimetry (DSC) measurements. Industrial target experiments were performed on duplex-coated SLM-printed MS1 steel specimens, which were simultaneously aged and salt-bath nitrided, followed by PVD coating with three different ceramic layers: DLC, CrN, and TiN. For reference, similar duplex-coated samples were used, featuring a bulk Böhler W720 maraging steel substrate that was solution annealed, precipitation hardened, and salt-bath nitrided in separate steps, following conventional procedures. The technological parameters (temperature and time) of the simultaneous nitriding and aging process were optimized by modeling the phase transformations of the entire heat treatment procedure using DSC measurements. A comparison was made based on the in-depth hardness profile estimated by the so-called expanding cavity model (ECM), demonstrating that the hardness of the surface layer of the coated composite material systems is determined solely by the type of the coatings and does not influenced by the type of the applied substrate materials (bulk or 3D printed) or its heat treatment (whether it is a conventional, multi-step treatment or a simultaneous nitriding + aging process). Based on the research work, a proposal is suggested for modernizing and improving the cost-effectiveness of producing aged, duplex-treated, wear-resistant ceramic-coated maraging steel. Full article

Erosion wear is a major cause of surface degradation in metallic materials exposed to harsh marine environments. In this study, the erosion wear resistance of the 18Ni300 maraging steel repaired by underwater direct metal deposition (UDMD) is investigated. Results show that UDMD is successfully applied to repair the 18Ni300 samples in underwater environment. Full groove filling and sound metallurgical bonding without cracks are achieved, demonstrating its potential for underwater structural repair. Microstructural analyses reveal good forming quality with fine cellular structures and dense lath martensite in the deposited layer, attributed to rapid solidification under water cooling. Compared to in-air DMD, the UDMD sample exhibits higher surface microhardness due to increased dislocation density and microstructural refinement. Erosion wear behavior is evaluated at 30° and 90° impingement angles, showing that wear mechanisms shift from micro-cutting and plowing at 30° to indentation, crack propagation, and spallation at 90°. The UDMD samples demonstrate superior erosion wear resistance with lower mass loss, particularly at 30°, benefiting from surface work hardening and microstructural advantages. Progressive surface hardening occurs during erosion due to severe plastic deformation, reducing wear rates over time. The combination of refined microstructure, high dislocation density, and enhanced work hardening capability makes UDMD-repaired steel highly resistant to erosive degradation. These findings confirm that UDMD is a promising technique for repairing marine steel structures, offering enhanced durability and long-term performance in harsh offshore environments. Full article

Selective laser melting (SLM) enables the production of complexly shaped metals with programmable mechanical responses, yet most lattice studies still rely on a single unit cell and a simple columnar build, severely restricting performance improvements. Here, we examine how combining distinct unit cells and rearranging them within the build volume affects the compressive behavior of SLM Corrax maraging stainless steel lattice structures. Three designs are additively manufactured as follows: a columnar cubic-FCCZ lattice, an alternating cubic and FCCZ lattice, and a hybrid lattice (cubic+FCCZ unit cell). In situ 2D digital image correlation (DIC) and finite element analysis (FEA) are used to resolve full-field strain evolution and failure modes under quasi-static compression. The hybrid lattice achieves the highest first maximum compressive strength (418 ± 5.78 MPa) and energy absorption (128.5 ± 6.83 MJ/m³), with its specific energy absorption (44.2 ± 1.48 kJ/kg) outperforming that of the columnar cubic-FCCZ lattice and alternating cubic and FCCZ lattice by 21.76% and 8.07%, respectively. The enhanced performance is attributed to the more uniform stress distribution and delayed shear band localization afforded by the hybrid lattice. These findings show that simultaneously optimizing unit cell geometry and arrangement can significantly expand the design space of metal lattices and provide a practical approach to improving the compressive strength and energy absorption capacity of load-bearing SLM components. Full article

This study evaluates the application of metal additive manufacturing—specifically the laser powder bed fusion (LPBF) process—for producing aluminium die-casting mould components, comparing 300-grade maraging steel inserts with conventional H13 tool steel. Efficient thermal management and mould durability are critical in aluminium injection moulding. Still, traditional machining limits the design of cooling channels, resulting in hot spots, accelerated wear, and a reduced service life. LPBF allows the fabrication of complex geometries, enabling conformal cooling channels to enhance thermal control. Component samples were manufactured using maraging steel via LPBF, machined to final dimensions, and subjected to duplex surface treatment (plasma nitriding + CrAlN PVD coating). Thermal performance, dimensional stability, mechanical properties, and wear resistance were experimentally assessed under conditions simulating industrial production. The results demonstrate that LPBF components with optimised cooling channels and surface engineering achieve higher thermal efficiency, an extended service life (up to 2.6×), improved hardness profiles (545 HV0.05 core, 1230 HV0.05 on nitrided surface and 2850 HV0.05 after PVD film deposition), and reduced maintenance frequencies compared to H13 inserts. The study confirms that additive manufacturing, combined with tailored surface treatments and optimised cooling design, overcomes the geometric and thermal limitations of conventional manufacturing, offering a reliable and productive solution for aluminium die-casting moulds. Full article

The objective of this study was to investigate the influence of additive manufacturing parameters, specifically using laser powder bed fusion (LPBF), and surface finishing methods on the corrosion rate and behavior of maraging steel M350 components. Samples were fabricated via LPBF employing varying laser powers (80 W, 100 W, and 120 W) and subsequently subjected to mechanical polishing. Corrosion performance was evaluated through 450 h immersion tests in a 3.5% aqueous NaCl solution and potentiodynamic polarization measurements. Microstructural characterization and surface topography assessments were performed using optical microscopy, scanning electron microscopy coupled with energy-dispersive spectroscopy (SEM-EDS), and profilometry. The results demonstrate a strong influence of temperature, manufacturing parameters, and polishing on corrosion processes. At room temperature, higher laser power reduced corrosion rates due to better powder consolidation and lower porosity, whereas at 45 °C, the trend reversed, with the highest corrosion rates observed for samples produced at 120 W. Mechanical polishing significantly reduced surface roughness (Ra from ~7–10 μm to ~0.6–1 μm) but did not improve corrosion resistance; in some cases, it increased corrosion rates, likely due to stress redistribution and exposure of subsurface defects. Potentiodynamic tests confirmed that higher laser power reduced corrosion current density for unpolished surfaces, but polishing increased current density at 80 W more than twofold. The findings indicate that optimizing LPBF process parameters is crucial for improving the corrosion resistance of M350 steel. High laser power (≥120 W) is beneficial at ambient conditions, while lower powers (80–100 W) perform better at elevated temperatures. Mechanical polishing alone is insufficient for enhancing resistance and should be combined with stress-relief and porosity-reduction treatments. These results provide guidelines for tailoring additive manufacturing strategies to ensure reliable performance of M350 steel in chloride-rich environments. Full article

This study addresses the critical need to enhance productivity in industrial automatic systems by optimizing the mass of moving components. The primary challenge is determining the complex, dynamic loads on structural elements, a prerequisite for effective redesign, without access to physical prototypes for experimental measurement. This paper presents a solution through a case study of a load-bearing pylon in a fine blanking plant, which is subject to inertial loads and shocks from pneumatic actuators and shock absorbers. To overcome this challenge, a high-fidelity multibody simulation model is developed to accurately estimate the dynamic loads on the pylon. This data is given as input to the topology optimization (TO) process, following the Design for Additive Manufacturing (DfAM) framework, to redesign the pylon for mass reduction using a Powder Bed Fusion-Laser Beam (PBF-LB). Two materials, EOS Aluminum Al2139 AM and EOS Maraging Steel MS1, are evaluated. The findings demonstrate that the integrated simulation and redesign approach is highly effective. The redesigned pylon’s performance is verified within the same simulation environment, confirming the productivity gains before manufacturing. A cost analysis revealed that the additively manufactured solution is more expensive than traditional methods, and the final choice depends on the overall productivity increase. This research validates a powerful methodology that integrates dynamic multibody analysis with topology optimization for AM. This approach is recommended in the design phase of complex industrial machinery to evaluate and quantify performance improvements and make informed decisions on the cost-effectiveness of introducing AM components without the need for physical prototyping. Full article

This article presents the results of the tribological performance of 20MnCr5 (1.7147) tool steel countersamples produced by Direct Metal Laser Sintering (DMLS), as a potential material for inserts or working layers of sheet metal forming tools. Tribological tests were performed using a roller-block tribotester. The samples were sheet metals made of materials with significantly different properties: Inconel 625, titanium-stabilised stainless steel 321, EN AW-6061 T0 aluminium alloy, and pure copper. The samples and countersamples were analysed in terms of their wear resistance, coefficient of friction (COF), changes in friction force during testing, and surface morphology after tribological contact under dry friction conditions. The tests were performed on DMLSed countersamples in the as-received state. The largest gain of countersample mass was observed for the 20MnCr5/EN AW-6061 T0 friction pair. The sample mass loss in this combination was also the largest, amounting to 19.96% of the initial mass. On the other hand, in the 20MnCr5/Inconel 625 friction pair, no significant changes in the mass of materials were recorded. For the Inconel 625 sample, a mass loss of 0.04% was observed. The basic wear mechanism of the samples was identified as abrasive wear. The highest friction forces were observed in the 20MnCr5/Cu friction pair (COF = 0.913) and 20MnCr5/EN AW-6061 T0 friction pair (COF = 1.234). The other two samples (Inconel 625, 321 steel) showed a very stable value of the friction force during the roller-block test resulting in a COF between 0.194 and 0.213. Based on the changes in friction force, COFs, and mass changes in friction pair components during wear tests, it can be concluded that potential tools in the form of inserts or working layers manufactured using 3D printing technology, the DMLS method, without additional surface treatment can be successfully used for forming sheets of 321 steel and Inconel 625. Full article

This study investigates the mechanical, tribological, and electrochemical behaviour of a novel precipitation-hardenable martensitic alloy produced by selective laser melting (SLM). The alloy was specifically engineered with an optimised composition, free from cobalt and molybdenum, and featuring reduced nickel content (7 wt.%) and 8 wt.% chromium. It has been developed as a cost-effective and sustainable alternative to conventional maraging steels, while maintaining high mechanical strength and a refined microstructure tailored to the steep thermal gradients inherent to the SLM process. Several ageing heat treatments were assessed to evaluate their influence on microstructure, hardness, tensile strength, retained austenite content, dislocation density, as well as wear behaviour (pin-on-disc test) and corrosion resistance (polarisation curves in 3.5%NaCl). The results indicate that ageing at 540 °C for 2 h offers an optimal combination of hardness (550–560 HV), tensile strength (~1700 MPa), microstructural stability, and wear resistance, with a 90% improvement compared to the as-built condition. In contrast, ageing at 600 °C for 1 h enhances ductility and corrosion resistance (Rp = 462.2 kΩ; Ecorr = –111.8 mV), at the expense of a higher fraction of reverted austenite (~34%) and reduced hardness (450 HV). This study demonstrates that the mechanical, surface, and electrochemical performance of this novel SLM-produced alloy can be effectively tailored through controlled thermal treatments, offering promising opportunities for demanding applications requiring a customised balance of strength, durability, and corrosion behaviour. Full article

This study systematically explores the synergistic effects of direct aging treatment (480 °C for 6 h) combined with cryogenic treatment (−196 °C for 8 h) on the mechanical properties and microstructural evolution of 18Ni300 maraging steel fabricated via selective laser melting (SLM). Three conditions were investigated: as-built, direct aging (AT6), and direct aging plus cryogenic treatment (AT6C8). Microstructural characterization was performed using optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), and X-ray diffraction (XRD), while the mechanical properties were evaluated via microhardness and tensile testing. The results show that the AT6C8 sample achieved the highest microhardness (635 HV_0.5) and tensile strength (2180 MPa), significantly exceeding the as-built (311 HV_0.5, 1182 MPa) and AT6 (580 HV_0.5, 2012 MPa) samples. Cryogenic treatment induced a notable phase transformation from retained austenite (γ phase) to martensite (α phase), with the peak relative intensity ratio ranging from 1.42 (AT6) to 1.58 (AT6C8) in the XRD results. TEM observations revealed that cryogenic treatment refined lath martensite from 0.75 μm (AT6) to 0.24 μm (AT6C8) and transformed reversed austenite into thin linear structures at the martensite boundaries. The combination of direct aging and cryogenic treatment effectively enhances the mechanical properties of SLM-fabricated 18Ni300 maraging steel through martensite transformation, microstructural refinement, and increased dislocation density. This approach addresses the challenge of balancing strength improvement and residual stress relaxation. Full article

To solve the problem of inadequate plasticity of traditional processing routes in improving the plasticity of novel Co-saving 18Ni (300) maraging steel, a cold deformation-cycle solution treatment process was developed. Through systematic characterization and tensile property testing, the study focuses on elucidating the impact of the number of solution treatments on the microstructure and mechanical behavior. The results showed that with a 30% cold deformation, three times of solution treatment at 860 °C for 10 min refined the original austenite grains (equivalent circle radius: 3.3 μm) and martensite structure (length and width: 7 μm and 1.3 μm, respectively) to the utmost extent. The grains became uniformly equiaxed, and the texture was eliminated, and a moderate content (4.5%) of retained austenite was formed. At this time, the material achieves the best match between strength (tensile strength of 1240 MPa) and plasticity (elongation of 9.93%), which are increased by 15.3% and 94.3%, respectively, compared with the traditional process. Mechanistic analysis revealed that grain refinement and uniform equiaxialization were the primary drivers for enhancing strength and plasticity. This study has demonstrated that the cold deformation-cyclic solution treatment process is an effective methodology for tailoring the microstructure and mechanical properties of maraging steel. Full article