<p>Powder bed fusion-laser beam (PBF-LB) is an additive manufacturing technique that uses a laser to selectively melt and fuse powdered metal into solid parts layer by layer. This study focuses on comparing additive manufactured steel components with conventionally manufactured components in the automotive industry. The use of maraging steel, known for its ultrahigh strength and optimal mechanical properties achieved through heat treatment, is examined. Since the authors represent the customer for the final produced products, the analysis of the parts is based on the industrial perspective side of view. The key findings give that the AM components exhibit a uniform microhardness profile and satisfactory levels of compressive residual stress, with the lowest hardness and residual stress levels found in an “as-built” specimen, while notably higher levels of hardness and compressive residual stress are achieved in heat-treated specimens. Defects such as porosity and lack of fusion—especially in specimen produced without preheating—were identified, highlighting the impact of printing parameters on the final material quality. The results indicate that, despite current limitations concerning production scale and cost, AM technologies present promising advantages, including design flexibility and environmental benefits, potentially revolutionizing component manufacturing in the automotive sector. Further research is recommended to optimize printing parameters and post-processing techniques to fully leverage the capabilities of additive manufacturing for high-performance automotive applications.</p>

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Material Examinations and Residual Stress Measurements of Additively Manufactured Steel Components

  • Rasha Alkaisee,
  • Henrik Karlsson

摘要

Powder bed fusion-laser beam (PBF-LB) is an additive manufacturing technique that uses a laser to selectively melt and fuse powdered metal into solid parts layer by layer. This study focuses on comparing additive manufactured steel components with conventionally manufactured components in the automotive industry. The use of maraging steel, known for its ultrahigh strength and optimal mechanical properties achieved through heat treatment, is examined. Since the authors represent the customer for the final produced products, the analysis of the parts is based on the industrial perspective side of view. The key findings give that the AM components exhibit a uniform microhardness profile and satisfactory levels of compressive residual stress, with the lowest hardness and residual stress levels found in an “as-built” specimen, while notably higher levels of hardness and compressive residual stress are achieved in heat-treated specimens. Defects such as porosity and lack of fusion—especially in specimen produced without preheating—were identified, highlighting the impact of printing parameters on the final material quality. The results indicate that, despite current limitations concerning production scale and cost, AM technologies present promising advantages, including design flexibility and environmental benefits, potentially revolutionizing component manufacturing in the automotive sector. Further research is recommended to optimize printing parameters and post-processing techniques to fully leverage the capabilities of additive manufacturing for high-performance automotive applications.