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Cited by 622Additive Manufacturing Materials and ProcessesHigh Temperature Alloys and CreepMicrostructure and Mechanical Properties of Steels

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Additive manufacturing of steels: a review of achievements and challenges

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Haghdadi, Nima, Laleh, Majid, Moyle, Maxwell, Primig, Sophie·2021·Journal of Materials Science
DOI 10.1007/s10853-020-05109-0
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Abstract

Metal additive manufacturing (AM), also known as 3D printing, is a disruptive manufacturing technology in which complex engineering parts are produced in a layer-by-layer manner, using a high-energy heating source and powder, wire or sheet as feeding material. The current paper aims to review the achievements in AM of steels in its ability to obtain superior properties that cannot be achieved through conventional manufacturing routes, thanks to the unique microstructural evolution in AM. The challenges that AM encounters are also reviewed, and suggestions for overcoming these challenges are provided if applicable. We focus on laser powder bed fusion and directed energy deposition as these two methods are currently the most common AM methods to process steels. The main foci are on austenitic stainless steels and maraging/precipitation-hardened (PH) steels, the two so far most widely used classes of steels in AM, before summarising the state-of-the-art of AM of other classes of steels. Our comprehensive review highlights that a wide range of steels can be processed by AM. The unique microstructural features including hierarchical (sub)grains and fine precipitates induced by AM result in enhancements of strength, wear resistance and corrosion resistance of AM steels when compared to their conventional counterparts. Achieving an acceptable ductility and fatigue performance remains a challenge in AM steels. AM also acts as an intrinsic heat treatment, triggering ‘in situ’ phase transformations including tempering and other precipitation phenomena in different grades of steels such as PH steels and tool steels. A thorough discussion of the performance of AM steels as a function of these unique microstructural features is presented in this review.

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Metadata

Authors
Haghdadi, N., Laleh, M., Moyle, M., & Primig, S.
Affiliations
  • UNSW Sydney (AU)
  • Deakin University (AU)
Corresponding author
  • Haghdadi, Nima
  • Primig, Sophie
ORCID
Venue
Journal of Materials Science
Publisher
Springer Science and Business Media LLC
Published
2020-08-26
Volume
56
Issue
1
Pages
64-107
ISSN
  • 0022-2461 (ISSN-L)
  • 1573-4803
DOI
10.1007/s10853-020-05109-0
OpenAlex
W3080496249
Cited by
622
References
1
Citations by year
2026: 92 · 2025: 118 · 2024: 123 · 2023: 123 · 2022: 114 · 2021: 49 · 2020: 3
FWCI
35.54
Type
journal article
Language
en
Open access
Licence
Locations
  • Journal of Materials Science (publishedVersion, cc-by)
  • Figshare (submittedVersion, cc-by)
  • UNSWorks (UNSW Sydney) (submittedVersion, cc-by-nc-nd)
Funders
  • University of New South Wales (DE180100440)
  • Department of Industry, Innovation and Science, Australian Government (DE180100440)
  • Australian Research Council (DE180100440)
Topics
  • Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
  • Physical Sciences › Engineering › Mechanical Engineering › High Temperature Alloys and Creep
  • Physical Sciences › Engineering › Mechanical Engineering › Microstructure and Mechanical Properties of Steels
Keywords
additive manufacturing of steel, laser powder bed fusion, directed energy deposition, austenitic stainless steel, maraging steel, precipitation hardened steel, tool steel, microstructure evolution, fine precipitates, in situ phase transformation, tempering, ductility, fatigue behavior, wear resistance, corrosion resistance, strength

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