Enabling Additive Manufacturing Applications for Structural Engineering with DED-LB of High-Strength Steels

Additive manufacturing (AM) of steel is gaining traction in the construction industry, offering the ability to fabricate complex geometries and optimize resource use. Among the AM techniques, Laser-Based Powder Directed Energy Deposition (DED-LB) is notable as it provides a compromise of relatively high productivity with respect to powder bed fusion and fine resolution with respect to arc based DED processes. However, the common steel grades often encounter challenges in meeting construction requirements, including limited compatibility with conventional structural steels concerning bolted and welded assemblies. This study tackles these challenges by developing the DED-LB process with a novel high-strength steel powder feedstock. Through an extensive experimental campaign, the research evaluates the processability of the material, focusing on achieving dense and crack-free steel components. The results highlight optimized deposition strategies providing high mechanical strength, opening new possibilities for its adoption in the construction sector for medium to large sized products.