Role of post-printing heat treatments and build orientation on the mechanical properties of additively manufactured maraging steel for power and energy applications

This study investigates the mechanical behavior of maraging steel components fabricated using direct metal laser sintering (DMLS) with varying build orientations within the XZ-plane and subjected to four post-printing heat treatments: as-built, solution-treated and then air-cooled, quenched, or furnace-cooled. The purpose is to evaluate the effects of multi-angle build direction within XZ-plane along with a selected post-printing heat treatment as a potential approach to mitigating the anisotropy and improving properties, including hardness, flexural strength, and impact energy. Samples were printed at angles of 0°, ±30°, ±45°, ±60°, and 90° and tested in both longitudinal and transverse directions. The results demonstrate a significant influence of both build angles and heat treatment on mechanical performance. Notably, isotropy was achieved only at a ±45° build angle. The findings are relevant to structural applications in many fields, including the energy sector and aerospace industry, where multidirectional loading and thermal gradients are prevalent. These insights contribute to the optimization of powder bed fusion strategies for fabricating components intended for mechanically demanding energy environments.