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.