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Selective Laser Melting of Maraging Steels Using Recycled Powders: A Comprehensive Microstructural and Mechanical Investigation

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Abstract

Selective laser melting (SLM) is an additive manufacturing (AM) technique designed to use a high energy density laser to fuse metallic powders for producing three-dimensional parts. So far, most studies of SLM have been focused on using virgin metal powders. There are few comprehensive studies on the microstructure and mechanical properties of SLM-produced parts using recycled powders, especially for maraging steels. In this study, we employ recycled steel powder (reused after 113 building cycles) in the SLM process to print multiple shaped components and systematically characterize the microstructure and mechanical properties (indentation, tensile, and Charpy testing). Our results show that maraging steel produced with recycled powder exhibit the nearly identical microstructure and mechanical properties (940 MPa yield strength, 1127 MPa ultimate tensile strength, 11 pct elongation, and 47.5 J room temperature impact fracture energy) to those produced using virgin powders. This study provides a useful generic guide towards using recycled metal powders in the SLM processing, promoting an economic solution to industrial productions.

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Acknowledgments

The authors greatly acknowledge the financial support from the Holistic Innovation in Additive Manufacturing Network (Hi-AM), Natural Sciences and Engineering Research Council of Canada (NSERC-RGPIN-2018-05731), and Dean’s Spark Assistant Professorship and XSeed Fund in the Faculty of Applied Science & Engineering at the University of Toronto. The authors thank Dr. A.T. Lausic, Mr. W. Byleveld, and Dr. K. Samk (EXCO Engineering) for their help with the experimental specimens, Dr. L. Wang (Shanghai Jiao Tong University) for his help with the XRD analysis, and Dr. Y. Liu (McGill University) for his assistance in Charpy impact tests. Mr. H. Sun acknowledges the Ontario Graduate Scholarship.

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  1. Haokun Sun and Xin Chu contributed equally.

Authors and Affiliations

  1. Department of Materials Science and Engineering, University of Toronto, Toronto, ON, M5S 3E4, Canada

    Haokun Sun, Xin Chu, Zhiying Liu, Azimi Gisele & Yu Zou

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  1. Haokun Sun
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Correspondence to Yu Zou.

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Manuscript submitted October 4, 2020; accepted February 1, 2021.

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Sun, H., Chu, X., Liu, Z. et al. Selective Laser Melting of Maraging Steels Using Recycled Powders: A Comprehensive Microstructural and Mechanical Investigation. Metall Mater Trans A 52, 1714–1722 (2021). https://doi.org/10.1007/s11661-021-06180-1

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