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<p>The increasing demand for materials that offer high strength and toughness has shifted attention toward ultrahigh-strength steel (UHSS). However, the complexities in shape and challenges in manufacturing reliability make the use of UHSS particularly difficult in applications within the aerospace, marine, and defense sectors<b>.</b> Directed energy deposition (DED) provides efficient production of geometrically intricate parts. This method allows for greater design flexibility and improved control over the mechanical properties of parts through various deposition strategies and parameter optimization. This review outlines the comparative advantages and limitations of powder-based and wire-based DED technologies. A detailed summary of the microstructure and mechanical properties of additively manufactured UHSS is provided, focusing on the effects of alloying elements, deposition direction, thermal history, and post-processing techniques aimed at enhancing microstructural homogeneity and mechanical performance. Finite element modeling serves as a powerful tool for predicting thermal cycles, residual stress, and distortion, while also inferring microstructural evolution. The significant challenges of anisotropy and porosity in DED-manufactured components can be mitigated through the optimization of process parameters using machine learning algorithms and finite element modeling, combined with the development of an innovative post-processing schedule. Research gaps in the literature are identified, and directions for future work are suggested.</p>

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A Review on Ultrahigh-Strength Steel Fabricated through Directed Energy Deposition

  • 期刊论文

  • 发表日期：

    2026年2月5日

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  • Niranjan D. Padawale,
  • Uday S. Dixit

摘要

The increasing demand for materials that offer high strength and toughness has shifted attention toward ultrahigh-strength steel (UHSS). However, the complexities in shape and challenges in manufacturing reliability make the use of UHSS particularly difficult in applications within the aerospace, marine, and defense sectors. Directed energy deposition (DED) provides efficient production of geometrically intricate parts. This method allows for greater design flexibility and improved control over the mechanical properties of parts through various deposition strategies and parameter optimization. This review outlines the comparative advantages and limitations of powder-based and wire-based DED technologies. A detailed summary of the microstructure and mechanical properties of additively manufactured UHSS is provided, focusing on the effects of alloying elements, deposition direction, thermal history, and post-processing techniques aimed at enhancing microstructural homogeneity and mechanical performance. Finite element modeling serves as a powerful tool for predicting thermal cycles, residual stress, and distortion, while also inferring microstructural evolution. The significant challenges of anisotropy and porosity in DED-manufactured components can be mitigated through the optimization of process parameters using machine learning algorithms and finite element modeling, combined with the development of an innovative post-processing schedule. Research gaps in the literature are identified, and directions for future work are suggested.