Process atmosphere and build location effects on maraging microstructure and resulting properties after Laser Powder Bed Fusion

The promising routes of metallic additive manufacturing favor the fabrication of refined functional components. Nonetheless, dealing with the Laser Powder Bed Fusion (L-PBF) parameters and costs for making the most of this technology is still an issue. The challenge gets bigger when considering less explored parameters, such as the process atmosphere and build location. So, this study aimed to address the main differences in microstructure, crystallography, mechanical properties, and surface finishing of maraging steel components manufactured under two different atmospheres (N₂ and a mixture of 75%Ar-25%He atmospheres) and three build locations arranged along the gas flow direction. Based on experimental characterizations, the porosity fraction, microstructural constituents and metallurgical flaws, phase composition and martensite matrix crystallographic parameters, macrotexture, mechanical properties, roughness, and surface residual stress were investigated and compared for the different manufacturing conditions. The porosity fraction had the most expressive changes with the gas type and the build location, reaching a 53% overall reduction under N₂ and a 112 to 302% rise for the front located sample compared to the others. The underlying mechanisms involved in the observed results, mainly related to process by-products behavior, were discussed. Broadly, the N₂ atmosphere stands out over the analyzed properties. These findings underscore the role of atmospheric selection in the LPBF process, considering the overall quality and performance of the fabricated material and the possibility of cost reduction.