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The current work targets improving metal-based Additive Manufacturing (AM) processes ; namely, Direct Metal Laser Sintering (DMLS). This research focuses on the manufacturing of steel alloys using the DMLS process, and high-strength 174-PH Stainless steel specifically. To achieve optimal material integrity and outstanding functionalities, different processing parameters impact on AM process are explored. Furthermore, development of a design framework based on general multi-scale models is suggested. The proposed framework includes: (1) Coupled thermal/microstructural prediction of DMLS process, (2) Establishing microstructure informed numerical models for properties and failure prediction for DMLS manufactured microstructures, (3) macroscale models with homogenized properties to be used for AM parts.

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