Research Progress of Laser Additive Manufacturing of Maraging Steels

doi:10.11900/0412.1961.2019.00129

Acta Metall Sin

2020, Vol. 56

Issue (1): 36-52 DOI: 10.11900/0412.1961.2019.00129

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Research Progress of Laser Additive Manufacturing of Maraging Steels

TAN Chaolin^1,²,ZHOU Kesong^1,²(

),MA Wenyou²,ZENG Dechang¹

1. School of Materials Science and Engineering, South China University of Technology, Guangzhou 510640, China
2. National Engineering Laboratory for Modern Materials Surface Engineering Technology, Guangdong Institute of New Materials, Guangzhou 510651, China

Cite this article:

TAN Chaolin,ZHOU Kesong,MA Wenyou,ZENG Dechang. Research Progress of Laser Additive Manufacturing of Maraging Steels. Acta Metall Sin, 2020, 56(1): 36-52.

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Abstract

Additive manufacture is recognized as a world-altering technology which triggered a world-wide intensive research interest. Here the research progress and application of the laser additive manufacturing maraging steel (MS) are systematically outlined. The advantages of selective laser melting (SLM) additive manufacture of MS is emphasized. The processing parameter and properties optimizations, build orientation based anisotropies, age hardening mechanism, gradient materials, and applications in die and moulds of SLM-processed MS are reviewed in detail. Achieving relative density of >99% in SLM-processed MS is effortless, owing to the wide SLM process window of MS. Mechanical properties of MS produced with optimized SLM processing parameters and post heat treatments are comparable to traditionally wrought parts. The build orientation hardly affects the property anisotropies of MS. The age hardening behaviour in MS follows Orowan bowing mechanism. MS-based gradient multi-materials (such as MS-Cu, MS-H13, etc.) with high bonding strength are fabricated by SLM, which provides a new approach to produce high-performance functionally gradient multi-materials components. Lastly, the application in conformal cooling moulds of SLM-processed MS is elucidated, and future research interests related to MS are also proposed.

Key words: selective laser melting maraging steel laser parameter gradient material conformal cooling

Received: 24 April 2019

ZTFLH:

TG665

Fund: Guangdong Academy of Sciences Projects(2019GDASYL-0502006);Guangdong Academy of Sciences Projects(2019GDASYL-0402004);Guangdong Academy of Sciences Projects(2019GD-ASYL-0402006);Guangdong Academy of Sciences Projects(2019GDASYL-0501009);Guangdong Academy of Sciences Projects(2017A070701027);Exterior Science and Technology Cooperation Programs of Guangzhou(201907010008);Guangdong Industrial Technology Research Institute (Guangzhou Research Institute of Nonferrous Metals) Project(2014B070705007)

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	Chaolin TAN
	Kesong ZHOU
	Wenyou MA
	Dechang ZENG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2019.00129 OR https://www.ams.org.cn/EN/Y2020/V56/I1/36

Fig.1 Schematic diagrams depicting the selective laser melting (SLM) system and SLM process parameters^[16]

Fig.2 Typical OM (a, d) and SEM (b, c, e, f) images of microstructures taken from the horizontal (a~c) and vertical (d~f) cross-sections of SLM-processed maraging steel (MS)^[43]

Table 1 Laser parameter, heat treatments and achievable properties of SLM-produced grade 300 maraging steels^{[16,38,45,50,51,52,53,54,55]}

Table 2 Post heat treatments and achievable properties of SLM-produced grade 300 maraging steels^{[4,16,38,46,49,51,52,54,56,57,58,59]}

Fig.3 Effect of different heat treatments on the tensile strength (R_m) (a) and break elongation (At) (b)^[60]

Fig.4 Effect of laser scan strategies on crystal orientations(a) X and X-Y scan^[61] (b) X-Y scan^[55]

Table 3 Effect of built directions on mechanical properties of SLM-produced grade 300 maraging steels^{[4,38,43,55,56,59,60]}

Fig.5 Atom probe tomography (APT) analysis of the aged MS (a)^[42] and APT analysis comparing precipitates in conventionally produced and laser metal deposition (LMD)-produced MS after age treatment (b)^[63]

Fig.6 TEM analyses of a SLM-produced MS sample after age-hardening (a~e)^[43](a) overview showing massive nanoprecipitates embedded in amorphous matrix(b) local magnification showing precipitate morphology and(c) zoom-in image taken from the given region of Fig.6b(d, e) high-resolution TEM images showing the coherent interface with elastic strain (d) and the complete coherent interface (e)

Table 4 Features of different SLM machines^[70,71,72]

Fig.7 Schematic diagram of SLM manufacturing of MS-Cu gradient multi-materials^[73]

Fig.8 Interfacial bonding mechanism analysis of SLM-produced Cu-MS^[73](a) SEM image of interfacial melt pool(b) image showing focused ion beam (FIB) extraction of a TEM sample(c) overview of TEM thin foil(d) EDX mapping of MS-Cu bonding region(e) schematics and formation mechanism of Marangoni convection in interfacial melt pool(f) TEM image of MS-Cu interface(g) HRTEM image taken from the region g in Fig.8d

Fig.9 Comparison between the SLM-produced conformal cooling and the traditional cooling moulds (a~c)^[79]

Fig.10 The MS conformal cooling mould processed by SLM hybrid tooling manufacturing technique (CNC—computerized numerical control)

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