In this research, we studied the influence of process parameters on the quality of selective laser melting of 18Ni300 maraging steel. The effects of laser power and scanning speed on the relative density and hardness of 18Ni300 were studied by single-factor experiment and the orthogonal experimental method. The relative optimal process parameters of 18Ni300 were obtained when the layer thickness was 0.03 mm, and the hatch space was 0.1 mm. The microstructures and mechanical properties of the samples formed under different process parameters were characterized. The results showed that the optimal hardness and relative density of the sample were 44.7 HRC and 99.98% when the laser power was 230 W and the scanning speed was 1100 mm/s, respectively; the microstructure of the material was uniform and dense, exhibiting few pores. Some columnar crystals appeared along the boundary of the molten pool due to vertical epitaxial growth. The orientation of fine grains at the boundary of the molten pool was random, and some coarse columnar crystals in the molten pool exhibited a certain orientational preference along the orientation. In the case of optimal process parameters, the SLM-formed 18Ni300 was composed of 99.5% martensite and 0.5% retained austenite; the indentation hardness was distributed in the range of 3.2–5 GPa. The indentation modulus was between 142.8–223.4 GPa, exhibiting stronger fluctuations than the indentation hardness. The sample’s mechanical properties showed obvious anisotropy, while the tensile fracture characteristics exhibited necking. The tensile fracture morphology was ductile, and large equiaxed dimples and holes could be observed in the fiber area, accompanied by tearing characteristics.

The optimal SLM conditions of 304L stainless steel were obtained by single factor and orthogonal tests. Results indicated that the optimal hardness (75 HRB) and Relative Density (RD 99.24%) could be obtained when the laser output power was 190 W, the scanning distance was 0.09 mm and the scanning speed was 800 mm/s. The microstructure of fish scales was uniform and compact with a few pores in the optimal sample. The fine particles were randomly distributed near the edge of the molten pool, and some preferred granular columnar crystal structures were formed. Abundant entanglement dislocations were observed between cell structures, forming dislocation clusters. Spherical nano-precipitates, rich in Si, Mn, and O, were also observed near cell structures. The mechanical properties of the specimens were highly anisotropic, and there were obvious necking and ductility at the tensile fracture.

Focused on the common problem of easy buckling of specimens in the tension-compression axial stress control fatigue test of automobile sheet steel, a stress fatigue test method for thickness less than 2.5 mm was proposed. For two kinds of automobile sheet materials with different strength levels and thicknesses, fatigue specimens with different widths of test section, parallel lengths, and fillet radii are designed. Without the anti-buckling device, high-cycle fatigue tests with a stress ratio R_s = −1 at different stress levels were carried out, and the shape and size of the fatigue specimens of automobile sheet materials were determined by the number of fatigue life cycles of specimens with different sizes under the same stress cycle form. The results show that for automobile sheet steel with a thickness of 1.0–2.5 mm, the recommended sizes of the uniform-gauge fatigue specimens are width of test section w = (1–3) t, parallel length L_p = (1–3) w, and fillet radius r = (3–10) t. For automobile sheet steel with a thickness less than 1 mm, because the time-displacement curve jitters during the test, it is recommended to install an anti-buckling device, specifically the anti-buckling device with mortise and tenon structure by self-design and with a flattop structure recommended by ISO 1099-2017, Metallic Materials—Fatigue Testing—Axial Force-Controlled Method.