Optimization of Selective Laser Melting Process for Maraging 300 Steel: Investigation the Impact of Parameters on Porosity, Microstructure, and Mechanical Properties

Abstract This study utilized the selective laser melting method to explore the influence of various process parameters, such as laser power, laser speed, hatch distance, and additional parameters, on the relative density, microhardness, porosity, surface roughness, and microstructure of maraging steel samples. Restriction angle, flow optimization, and time homogenization which was called additional parameters in this study were independently evaluated in both “on” and “off” conditions. Additionally, volumetric energy density was employed to measure the combined impact of the process parameters. Furthermore, volumetric energy density has been used to evaluate the combined impact of the process parameters. In the scenerio where additional parameters are “on”, the microhardness value remained constant even with an increase in volumetric energy density. This signifies a positive impact of incorporating additional parameters in productions that necessitate high energy intensity. However, in the case where additional parameters are “off”, a substantial decrease in the microhardness value was observed at volumetric energy density levels surpassing approximately 60 J/mm3. The optimized process parameters have been determined using the full factorial design method, resulting in three ideal solutions. Among these three optimal solutions, two of the optimal solutions involve the utilization of additional parameters, which are advanced features of the machine. This study offers a particular advantage in processes aiming for low porosity, low surface roughness, and high hardness by employing advanced parameters.