Technology overview and investigation of the quality of a 3D-printed maraging steel demonstration part

Abstract

Additive manufacturing (AM) has gained significant traction in the production of high-performance metallic components, yet concerns persist regarding the consistency of powder materials and the mechanical properties of 3D-printed parts. This study addresses these challenges through a detailed analysis of a maraging steel part manufactured using laser powder bed fusion. The demonstration part was evaluated for geometric accuracy, surface roughness, chemical composition, microstructure, and mechanical properties, including hardness and density. The findings revealed that 3D-printed maraging steel components can achieve high levels of dimensional precision and mechanical integrity, making them suitable for demanding applications. Despite these promising results, the study highlighted the need for improved powder quality control and accurate composition measurement to ensure the consistent production of reliable parts. The non-destructive hardness testing method applied in this study proved effective for predicting tensile strength, offering a streamlined approach to quality assurance. These results contribute to a growing body of research and knowledge supporting the adoption of AM for producing critical mechanical components, while underscoring the need for further investigation into quality assurance and standardized non-destructive testing procedures for high-performance metal AM parts.

Keywords

3D printing / Additive manufacturing / Laser powder bed fusion / Steel 1.2709 / Maraging steel / Quality analysis / Mechanical properties

Funding

The authors gratefully acknowledge: the support provided by the Foundation for Science and Technology (FCT) of Portugal, within the scope of the project of the “Research Unit on Materials, Energy, and Environment for Sustainability” (proMetheus), Ref. UID/05975/2020, financed by national funds through the FCT/MCTES; and the support provided within the scope of the “Agenda DRIVOLUTION: Transition to the Factory of the Future,” project no. C632394276-0046698 with operation code 02/C05-i01.02/2022.PC644913740-00000022, within the framework of the Agendas/Mobilizing Alliances for Reindustrialization, Notice no. 2022-C05i0101-02, project 23, of the Recovery and Resilience Plan (PRR) of Portugal.

Conflict of interest

The authors declare that they have no competing interests.

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