In the relentless pursuit of stronger, more durable materials for the energy sector, researchers have long grappled with the challenges posed by additive manufacturing. Now, a groundbreaking study from Northwestern Polytechnical University in Xi’an, China, offers a promising solution to enhance the toughness of maraging steels used in critical energy applications.
Maraging steels, known for their exceptional strength and hardness, are increasingly used in the energy sector for components that demand high performance under extreme conditions. However, the high oxygen content in the powders used for additive manufacturing can lead to oxide inclusions, significantly reducing the material’s toughness. This is where the work of Chao Wang, a researcher at the State Key Laboratory of Solidification Processing, comes into play.
Wang and his team have been exploring the use of deoxidizers to control oxide inclusions in laser powder bed fusion (L-PBF) processed maraging steels. Their findings, published in a recent issue of Materials Research Letters, reveal that the type and amount of deoxidizer used can dramatically impact the material’s properties.
The researchers tested three different deoxidizer strategies. A strong deoxidizer, aluminum, formed fine Al2O3 particles, but these grew significantly during heat treatment. A weak deoxidizer combination of silicon and manganese produced low-melting-point oxides that also grew substantially. However, a trace deoxidizer approach, using minimal amounts of silicon, manganese, aluminum, and titanium, resulted in the finest oxide particles and the highest cryogenic toughness.
“The trace deoxidizer approach seems to offer the best of both worlds,” Wang explains. “It minimizes oxide growth during heat treatment and maximizes toughness, which is crucial for energy sector applications.”
The implications of this research are significant for the energy sector. As the demand for more efficient and durable materials grows, so does the need for innovative solutions to the challenges posed by additive manufacturing. By optimizing deoxidizer content, manufacturers can produce maraging steels with enhanced toughness, making them suitable for a wider range of applications in the energy sector.
Moreover, this research could pave the way for further developments in the field of additive manufacturing. As Wang notes, “Understanding how to control oxide inclusions is just the beginning. There’s still much to explore in terms of optimizing other aspects of the manufacturing process.”
The study, published in the English-translated Materials Research Letters, underscores the potential of additive manufacturing to revolutionize the energy sector. By addressing the challenges posed by oxide inclusions, researchers like Wang are paving the way for a future where stronger, more durable materials are the norm. As the energy sector continues to evolve, so too will the materials that power it, and this research is a significant step in that direction.