In the selective laser melting (SLM) additive manufacturing process of Inconel 718, the emergence of Laves and δ precipitate phases in the γ matrix during or after heat treatment is a critical consideration. This study comprehensively assesses the microstructures and mechanical properties of Inconel 718 alloy produced through SLM under varied conditions: as-built (AB), homogenization + solution + aging (HSA), homogenization + aging (HA), and solution + aging (SA). Additionally, the impact of building orientation, whether horizontal (H) or vertical (V), is investigated. The AB specimens oriented horizontally display a columnar melt pool structure, with dimensions roughly between 300 and 400 μm. In contrast, the AB specimens aligned vertically show an elongated river-like structure of melt pools, with their sizes approximately at 250 μm. From the detailed microstructural analysis, the findings reveal that the as-built specimens lack γ′ and γ″ precipitates in their microstructure. Conversely, in heat-treated specimens, both the γ′ and γ″ phases are evident. Notably, Inconel 718 alloy specimens subjected to SLM fabrication and SA heat treatment demonstrate optimal mechanical performance. Notably, SA exhibits an average hardness of 476 HV for the horizontal specimen, which is 51.1% higher than that of AB specimens. The morphology and distribution of the δ phase in the γ matrix emerge as decisive factors influencing high-temperature performance. In SA specimens, the dissolution of brittle Laves phases occurs, and the presence of the δ phase at the grain boundary imparts superior properties during high-temperature tensile testing, including excellent yield and ultimate tensile strength. The presence of the granular-δ phase in the SA specimens resulted in a tensile strength of 1422 MPa and a yield strength of 1236 MPa, which are the highest values among all the specimens. SA has a tensile strength of 1120 MPa and a yield strength of 974 MPa at 650 °C.

Additive manufacturing technologies for metallic materials based on powder bed fusion have enormous industrial potential. In this study, we manufactured 18Ni-300 maraging steel using the powder bed fusion (PBF) process and investigated the effects of annealing temperatures of 430 °C, 490 °C, and 550 °C for 3 h on its microstructure, tensile fracture mechanism, and wear properties compared with the as-built specimen. The results show that annealing heat treatment effectively improved the dry sliding friction, wear properties, and room temperature tensile properties compared to the as-built specimen. Compared to other aging-treated samples, specimens that underwent heat treatment in optimal settings had superior properties. With optimal heat treatment, while melt pool boundaries remained, the cellular and columnar structures became finer compared to the un-treated specimens, and the number of dimples decreased. Consequently, the hardness and tensile strength improved by approximately 56.17% and 40.63%, respectively. The 18Ni-300 maraging steel sample that underwent heat treatment at optimal settings exhibited a coefficient of friction approximately 33.33% lower than the as-built alloy.

Residual stresses generated during the casting process significantly affect the reliability of the final product, making accurate prediction and analysis of these stresses crucial. In particular, to minimize the difference between simulation results and actual measurements, it is essential to develop predictive simulations that incorporate microstructural characteristics. Therefore, in this study, residual stress prediction simulations were conducted for aluminum components manufactured by high-pressure die casting (HPDC), and measurement locations were selected based on the simulation results. Subsequently, the microstructural characteristics at each location (Si and intermetallic compounds) were quantitatively analyzed, and significant factors affecting residual stress were identified through design of experiments (DOE). As a result, Si sphericity (p-value ≤ 0.05) was observed to be the most significant factor among Si area fraction, IMC area fraction, and Si sphericity, and the residual stress and Si sphericity showed a positive interaction due to the rapid cooling rate and inhomogeneous microstructure distribution. Furthermore, the study demonstrated the effectiveness of DOE in clearly distinguishing the significance of variables with strong interdependencies.