LAUSR

Abstract The present work aimed to decrease the surface roughness of maraging steel (MS) by selective laser melting (SLM) using large pulsed electron-beam (LPEB) irradiation as a post-treatment. The MS samples were fabricated using different combinations of laser power, scanning speed, hatch distance, and build angle. The morphological features, surface roughness, phase content, and corrosion resistance of the MS samples in their as-fabricated (ASF) state were compared after LPEB irradiation. The ASF SLM-MS samples exhibit the presence of partially melted particles that spread over the entire surface and many cracks in both the longitudinal and transverse directions. A higher arithmetical mean height (Sa: 2−17 μm), large variations in Sa measured at various locations, and a strong dependence of Sa on build angle were also observed. Post-treatment by LPEB irradiation removed the partially melted particles, while reflow of the molten mass filled the cracks and voids and facilitated the formation of a uniform surface with a bright metallic finish. This has resulted in a significant decrease in Sa (0.50–4.50 μm) and a smaller variation in Sa measured at different locations. Body-centered cubic α-martensite was the predominant phase for the ASF SLM-MS samples, along with a small fraction face-centered cubic γ-austenite phase. After LPEB irradiation, the martensite was reverted to the austenite phase. The corrosion resistance of the LPEB-irradiated samples was moderately better than that of the ASF SLM-MS samples. The uniform surface morphology, removal of partially melted particles, absence of pores and cracks, decrease in Sa, and moderate improvement in corrosion resistance suggests that LPEB irradiation can be used as a post-treatment for SLM-MS samples.