Sensitivity of direct metal laser sintering Maraging steel fatigue strength to build orientation and allowance for machining

This work deals with the effect of build orientation and of allowance for machining on DMLS‐produced Maraging Steel MS1. The experimental results, arranged by tools of Design of Experiment, have been statistically processed and compared. The outcomes were that, probably due to effect of the thermal treatment, machining, and material properties, the aforementioned factors do not have a significant impact on the fatigue response. This made it possible to work out a global curve that accounts for all the results, consisting in a high amount of data points. This can be regarded as one of the most complete and reliable fatigue models in the current literature. Fractographic and micrographic studies have been performed as well, to individuate the crack initiation points, usually located at subsurface porosities, and to investigate the location of internal inclusions and the actual martensitic microstructure along the stacking direction and on the build plane.