Directed Energy Deposition of Low‐Alloyed Steels: An Insight on Microstructural and Mechanical Properties

Low‐alloyed steels are used for a variety of different applications like bearings or gears. Additive manufacturing technologies like directed energy deposition (DED‐LB/M) allow for a fast and close‐to‐contour fabrication of sophisticated products without excessive waste of material. However, the DED‐LB/M process cannot be considered as state‐of‐the‐art for this group of materials. This study presents findings on the material properties of the additively manufactured low‐alloyed steel Bainidur AM by means of DED‐LB/M. This includes studies on the mechanical properties (hardness, compression strength) as well as the microstructural properties (scanning electron microscopy [SEM]). The microstructure in the as‐built state appears like a bainitic–martensitic one with shares of retained austenite which is not fully transformed during cooling. As a differentiation is barely possible from the SEM images, a plethora of investigations is further used to assess the microstructure. As‐built samples possess a good combination of ductility and hardness. Furthermore, the specimens are characterized by a good tempering stability up to 600 °C. This tempering stability is characterized by a homogeneous hardness of around 400 HV1 for all temperatures. In contrast, the conventionally hardened specimens show a drop‐off in material hardness, further indicating the excellent material properties of additively manufactured Bainidur AM. This work shows key findings on the processing of case‐hardening steels by means of directed energy deposition (DED‐LB/M). By applying different investigations methods, it can be found that the underlying microstructure is bainite‐dominated rather than a tempered martensitic one, which results in excellent material properties both in the as‐built and tempered state.