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The Variation of Mechanical Properties of M300 Maraging Steel Manufactured with Varying Process Parameters in Laser Powder Bed Fusion
Laser power bed fusion (L-PBF) is a type of additive manufacturing (AM) that uses layers
of powdered metal and a laser to manufacture a part in a layer-by-layer fashion. L-PBF uses a
variety of process parameters that ultimately determine the overall quality and mechanical
properties of a print. The ability to alter parameters allows for the utilization of various metals in
this form of AM. Maraging 300 steel (M300) is a material of particular interest due to its combined
tensile strength and high strength-to-weight ratio. By using an assortment of parameters and
comparing the resulting mechanical properties it can be determined which process parameters
result in a more favorable part to be used in a variety of applications. A favorable process parameter
set was selected for future use. This study aims to determine which process parameters result in
the best overall mechanical properties of M300 manufactured using L-PBF.Mechanical Engineerin
Process–Structure–Property Relationship Development in Large-Format Additive Manufacturing: Fiber Alignment and Ultimate Tensile Strength
Parts made through additive manufacturing (AM) often exhibit mechanical anisotropy due to the time-based deposition of material and processing parameters. In polymer material extrusion (MEX), printed parts have weak points at layer interfaces, perpendicular to the direction of deposition. Poly(lactic acid) with chopped carbon fiber was printed on a large-format pellet printer at various extrusion rates with the same tool pathing to measure the fiber alignment with deposition via two methods and relate it to the ultimate tensile strength (UTS). Within a singular printed bead, an X-ray microscopy (XRM) scan was conducted to produce a reconstruction of the internal microstructure and 3D object data on the length and orientation of fibers. From the scan, discrete images were used in an image analysis technique to determine the fiber alignment to deposition without 3D object data on each fiber’s size. Both the object method and the discrete image method showed a negative relationship between the extrusion rate and fiber alignment, with −34.64% and −53.43% alignment per extrusion multiplier, respectively, as the slopes of the linear regression. Tensile testing was conducted to determine the correlation between the fiber alignment and UTS. For all extrusion rates tested, as the extrusion multiplier increased, the percent difference in the UTS decreased, to a minimum of 8.12 ± 14.40%. The use of image analysis for the determination of the fiber alignment provides a possible method for relating the microstructure to the meso-property of AM parts, and the relationship between the microstructure and the properties establishes process–structure–property relationships for large-format AM