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Optimal Process Conditions for Powder Bed Fusion and Analysis of Properties of Maraging Steel

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Abstract

Powder bed fusion (PBF), an additive manufacturing technology, has been widely used in the manufacturing field to create complex designs. Most PBF process studies have investigated the effect of laser power and scan speed on the mechanical properties and porosity of microstructure. In this study, five process conditions were selected to obtain superior properties of maraging steel, which were validated by absolute density analysis, hardness, and tensile tests. Maraging steel exhibits diverse mechanical properties depending on the heat-treatment combinations of solution annealing and aging. Mechanical property tests were conducted to compare the various temperature properties of the fabricated maraging steel under optimal conditions. Maraging steel exhibited a hardness of 612.7 HV and a tensile strength of 1925.6 MPa at 25 °C, and the strength was greater than 1000 MPa at temperatures below 600 °C. Additionally, the applicability of a fabricated die for maraging steel was investigated. The maraging steel die and American Iron and Steel Institute (AISI) D2 were analyzed by a forging process based on die load data sensing with a piezoelectric bolt. The maximum loads of the sensor in horizontal and vertical directions were 24.7% and 15.8% lower for the fabricated die than those of AISI D2. The findings confirm that the fabricated maraging steel is a suitable manufacturing process for commercial processes and can be used to manufacture dies with complex shapes.

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Acknowledgements

This study was conducted with support from the Korea Institute of Industrial Technology as “Digital transfer project of Ppuri technology master know-how (KITECH UR-22-0041)”. We would like to thank Editage (www.editage.co.kr) for English language editing.

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Author notes

  1. A Ra Jo and Ji Seob An have contributed to the work equally and should be regarded as co-first authors.

Authors and Affiliations

  1. Smart Manufacturing Technology R&D Group, Korea Institute of Industrial Technology, Daegu, 42994, Republic of Korea

    A Ra Jo, Ji Seob An, Sun Hyung Kim, Dong Yong Park & Sun Kwang Hwang

  2. Department of Mechanical Engineering, Pusan National University, Busan, 46241, Republic of Korea

    A Ra Jo, Ji Seob An & Young Hoon Moon

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  1. A Ra Jo
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  2. Ji Seob An
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Contributions

ARJ: Conceptualization, methodology, data analysis, writing—original draft. JSA: methodology, data analysis, visualization, writing. SHK: investigation, figure drawing, methodology. DYP: formal analysis, discussion. YHM: conceptualization, formal analysis, discussion. SKH: validation, writing—review and editing, supervision, funding acquisition.

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Correspondence to Sun Kwang Hwang.

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Jo, A.R., An, J.S., Kim, S.H. et al. Optimal Process Conditions for Powder Bed Fusion and Analysis of Properties of Maraging Steel. Met. Mater. Int. 29, 2865–2877 (2023). https://doi.org/10.1007/s12540-023-01437-3

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