# Design of a Cobalt‐Free Maraging Steel with Ultra‐High Strength of 2.3 GPa Through Additive Manufacturing

## TL;DR

A new cobalt-free maraging steel designed for 3D printing achieves ultra-high strength and good ductility, offering a sustainable alternative to traditional alloys.

## Contribution

A computationally designed cobalt-free maraging steel with ultra-high strength and crack resistance for additive manufacturing.

## Key findings

- The alloy achieves a tensile strength of 2.3 GPa and 5.7% elongation after aging.
- High-density core-shell Ni3Ti/NiAl nanoprecipitates enhance strength and ductility.
- Printing results in equiaxed grains and uniform elemental distribution, improving material properties.

## Abstract

Additive manufacturing (AM) is a revolutionary technology that enables the production of components with complex geometries and exceptional properties, which has attracted significant research interest. However, one potential challenge associated with additive manufacturing is its increased susceptibility to cracking resulting from the incorporation of high alloying elements. Furthermore, the formation of brittle Laves phases is frequently observed in cobalt‐containing maraging steels, which significantly compromises the ductility of these materials following heat treatment. Here, we demonstrate that by minimizing the crack susceptibility of the steel and introducing high‐density Ni3Ti and NiAl nanoprecipitates with a core‐shell structure, these challenges are simultaneously addressed. The cobalt‐free maraging steel, with a composition of Fe‐18.5Ni‐4.6Mo‐1.5Ti‐0.9Al‐0.05C‐0.01Y, is computationally designed to achieve high crack resistance and martensite start temperature. The alloy exhibits a transition from columnar to equiaxed grains and a uniform elemental distribution after printing. After aging, it achieves exceptional mechanical properties, with a tensile strength of 2.3 GPa and an elongation of 5.7%, making it a more promising alternative to conventional alloys. This study provides a potential avenue toward the design of cost‐effective, high‐performance, and sustainable alloys for additive manufacturing.

A computationally designed, cobalt‐free maraging steel tailored for additive manufacturing achieves an ultra‐high tensile strength of 2.3 GPa with 5.7% elongation. This exceptional strength‐ductility synergy stems from high‐density core‐shell Ni3Ti/NiAl nanoprecipitates, a crack‐resistant composition, and a fine equiaxed grain structure enabled by laser powder bed fusion.