Maraging steels possess low carbon content and demonstrate a remarkable amalgamation of ultra-high strength, ductility, machinability, dimensional stability, and good fracture toughness. These alloys find widespread application in die casting and tooling industries. Moreover, there is potential for utilization as spring steel, particularly in sectors such as food and automotive, where primary requisites include stiffness, high strength, and ductility. The production process for these steels is intricate, and alternatively, additive manufacturing (AM) emerges as a cost-effective method for generating complex geometries with precise attributes such as microstructure, mechanical properties, and corrosion resistance within reduced lead times.

The absence of carbon in maraging steels results in the formation of relatively soft and tough lath martensite during solidification, exhibiting a heightened resistance to cracking during AM processing. The elevated strength levels are achieved through the dispersion of intermetallic nanoprecipitates uniformly, facilitated by a subsequent ageing treatment. The presence of Retained Austenite (RA) and reversed austenite in maraging steels plays a crucial role in governing their mechanical properties.

Despite extensive research efforts in the scientific community to establish correlations between input parameters (such as particle size distribution, chemical composition, process parameters, strategies, etc.) and output parameters (including mechanical properties, relative density, and microstructure), the impact of RA and reversed austenite, as well as the influence of the heat treatment process, remains unexplored.

This study concentrates on the preliminary findings related to additive manufacturing of maraging steels for automobile spring applications, using commercially available precursor powders. The discussion encompasses various process parameters and microstructural properties of the AM samples.