The problem of insufficient wear resistance of maraging steels (MSt) has so far been solved mainly by the use of the thermochemical nitriding process, which has a number of limitations and disadvantages. In the present work, for MSt parts manufactured by laser powder bed fusion (LPBF), a more flexible laser alloying process was suggested as an alternative surface hardening process. The purpose of the present work is to give a better understanding on the possible hardening effect obtainable when amorphous boron is used as an alloying additive in relation with microstructural evolution and specific process parameters and to promote further development of this technology. For the alloying, a one kilowatt CO2 laser was applied at 0.5–4.0 mm laser spot and 250–1500 mm/min laser operating speed, providing 50,955–796 W∙cm−2 power density and 24.0–4.0 J∙mm−1 heat input. Before laser processing, surfaces were covered with amorphous boron. The appropriate melt pool geometry was obtained at 0.5 mm laser spot, for which XPS analysis revealed an increase in boron concentration from ~3.1 to ~5.7 wt.% with a laser speed increase from 500 to 1500 mm/min. XRD analysis revealed domination of Fe3B type borides along with the presence of FeB, Fe2B, Ni4B3 borides, austenitic and martensitic phases. The microstructure of modified layers exhibited evolution from hypoeutectic microstructure, having ~630–780 HK0.5 hardness, to superfine lamellar nanoeutectic (~1000–1030 HK0.2) and further to submicron-sized dendritic boride structure (~1770 HK0.2). Aging of laser-boronized layers resulted in the change of phase composition and microstructure, which is mainly expressed in a plenty precipitation of Mo2B5 borides and leads to a reduction in hardness—more significant (by ~200–300 HK0.2) for hypoeutectic and hypereutectic layers and insignificant (by ~50 HK0.2) for near-eutectic. With the application of the laser boronizing technique, the hardness of MSt parts surface was increased up to ~three times before aging and up to ~2.3 times after aging, as compared with the hardness of aged MST part.

The development of new efficient, economical, and safe methods for strengthening the working surfaces of parts is an important task in the field of improving the reliability and resourcefulness of critical equipment and structures. In the present paper, laser boronizing is investigated as an alternative method for improving the wear resistance of maraging steel parts manufactured by laser powder bed fusion (LPBF). After LPBF, the specimens’ surface was covered with an amorphous boron paste (0.03–0.6 mm) and laser processed with a continuous-wave fiber laser in melting mode (λ—1070 nm; power—300 W; spot Ø—1.0 mm) at 500–1500 mm/min laser beam scanning speeds. Scanning electron microscopy, X-ray microanalysis, Knoop hardness, and dry sliding wear tests were applied to investigate the geometry, microstructure, hardness and its distribution, heat-affected zones, wear resistance, and wear mechanism of the alloyed layers. The boronized layers of thickness ~280–520 µm with microstructure from hypoeutectic to borides’ mixture were obtained, whose hardness varied from ~490 to ~2200 HK0.2. With laser boronizing, the wear resistance was improved up to ~7.5 times as compared with aged LPBF samples. In further method development, the problem of thermal cracking and softening of the heat-affected zone should be solved.

In the present study, surface laser boronizing technique was applied to improve wear resistance of maraging steel (MSt) parts manufactured by selective laser melting (SLM). Samples for investigation were manufactured of DIN 1.2709 steel powder using Concept Laser M3 equipment. Continuous 1 kW CO2 laser was applied at 0.5 mm laser spot and 500-1500 mm/min laser operating speed, providing power density of 50955 W•cm -2 and heat input between 12.0 and 4.0 J•mm -1 , respectively. Before laser-processing, amorphous boron paste was pre-placed on samples' surface. XPS analysis revealed increase in boron concentrations from ~3.1 wt% to ~5.7 wt% with laser speed increase from 500 mm/min to 1500 mm/min. XRD analysis revealed domination of Fe3B type borides along with presence of FeB, Fe2B type borides and presence of reflections attributable to austenitic and martensitic phases. The microstructure of laser-boronized layers exhibits evolution from fine dendritic boride-based eutectic plus Fe-based solid solution microstructure having ~630-780 HK0.5 hardness (at 500 and 750 mm/min laser speed) to superfine lamellar nanoeutectic (at 1000 and 1250 mm/min; ~1000-1030 HK0.2) and further to submicron-sized boride structure (at 1500 mm/min; ~1770 HK0.2). The obtained hardness is up to three times higher than that of MSt after aging (~600 HK), indicating that laser boronizing technique may be promising in term of the improve of MSt wear resistance.

Due to the possibility to produce the parts with complex internal and external geometries, selective laser melting (SLM) process attracts growing interest in various fields of engineering segments such as aircraft, aerospace, biomedical, automotive, marine industries and tooling. Maraging steels, having excellent weldability and high resistance to thermal fatigue due to the lack of carbon, has showed good suitability for SLM [1]. However, owing to the limited hardness and wear resistance, maraging steels has limited application at the harsh wear conditions [4]. In this study, the possibility to improve the surface characteristics of DIN 1.2709 steel SLM parts by application of laser alloying technology is evaluated. The surface of SLM part was laser processed at various laser spot diameters and varying laser scanning speeds from 500 to 1500 mm⋅min-1, with and without preposition of alloying element. The power density was provided in the range from ~0.8⋅103 W⋅cm-2 to ~51⋅103 W⋅cm-2 and heat input – from 4 to 12 J⋅mm-1. The effect of laser processing parameters and presence of alloying element on the geometry of obtained processed passes and hardness of surface was evaluated. It was determined, that the application of CO2 continuous laser at the parameters of 1 kW laser power, 0.5 mm laser beam spot diameter and laser scanning speed in the range between 500 mm⋅min-1 and 1250 mm⋅min-1 allows obtaining laser pool of acceptable geometry and sizes directly on as-manufactured SLM part surface without any pre-processing. The increasing scanning speed to 1500 mm⋅min-1 or spot size to 2.0 and 3.0 mm results in too small pool depth and unstable pool geometry. The laser processing with preposition of alloying element layer provided surface alloying effect of the maraging steel SLM part. The hardness of processed surface areas ranged between ~600 HV0.2 at the lowest scanning speed and ~1770 HV0.2 at the highest speed, what is from 18% to ~3.5 times higher, as compared with maximum hardness of 1.2709 maraging steel after aging (~58 HRC or ~510 HV).