Tomography of Laser Powder Bed Fusion Maraging Steel

The presence of defects in additive manufactured maraging steel is a widespread problem as its dependence on processing parameters significantly influences it. Using X-ray computed tomography, along with optical microscope data limited to 2D images, quantifies the internal porosity present on a compact tension sample typically employed in fatigue testing. The primary goal of this research is to analyse the pores obtained after the fabrication of a compact tension sample and their main definition parameters, such as sphericity, aspect ratio, surface, and volume, and obtain validation of which method is valid for each of the parameters analysed. The current study aims to enhance the understanding of defects in maraging steel samples through non-destructive 3D analysis. Conventional 2D analyses are limited to surface measurements, providing incomplete information. The proposed method will provide a comprehensive understanding of the defects inside the maraging steel sample, thereby improving the reliability of this material for further applications. This study will contribute to academic and industrial communities by providing a novel approach to analysing maraging steel samples and, ultimately, developing improved materials for various applications. The study’s findings reveal that most pores are produced by gases that are trapped in the fabrication process, and keyhole pores only appear near the surface.