Additively Manufactured Maraging Steel: Influence of Heat Treatment on Corrosion and Mechanical Properties

The advancement of additive manufacturing (AM) technologies, particularly laser powder bed fusion (LPBF), has enabled the production of complex components with enhanced mechanical properties and shorter lead times compared to conventional manufacturing processes. This study focuses on the characterization of maraging steel (EOS MS1) fabricated by LPBF technology using an EOS M 290 system. Three material groups were investigated: a conventionally manufactured tool steel (95MnWCr5) serving as a reference, LPBF-produced maraging steel in the as-built condition, and LPBF-produced maraging steel subjected to post-processing heat treatment. The samples were thoroughly examined using optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), glow discharge optical emission spectroscopy (GDOES), electrochemical corrosion analyses in a 3.5% NaCl solution, and Vickers microhardness measurements. Electrochemical tests revealed that heat-treated LPBF maraging steel samples exhibited slightly increased corrosion current densities relative to their as-built counterparts, attributed to the formation of Ti-rich and Ni-rich precipitates during aging, creating localized microgalvanic cells. Despite the increased corrosion susceptibility, hardness measurements clearly demonstrated enhanced hardness and mechanical properties in heat-treated samples compared to the as-built state and conventional tool steel reference. The findings underscore the importance of optimized LPBF parameters and controlled post-processing heat treatments in balancing mechanical performance and corrosion resistance. Consequently, LPBF-produced maraging steels hold considerable promise for tooling and industrial applications where high strength, dimensional stability, and acceptable corrosion behavior are required.