This study explores the evolution of solidification microstructure of a laser powder bed fusion (L-PBF) martensitic stainless steel during solution annealing and aging. Quasi in-situ experiments using electron backscatter diffraction (EBSD) revealed that the finer, more equiaxed microstructure below the melt pool was susceptible to recrystallization and grain growth during solution annealing. The two distinct solidification microstructures below and inside the melt pool converged into a uniform grain morphology after solution annealing and aging processes. Graphical Abstract: (Figure presented.)

Maraging steel (MS1)-tool steel (P20) bimetals additively manufactured using the laser powder bed fusion technique were studied under different heat treatment cycles and loading conditions. The hardening of P20 and aging of MS1 were performed sequentially on the hybrid samples. The interfacial characteristics and microstructural evolution of the bulk materials were studied using various advanced electron microscopy techniques. The post-processing procedures successfully produced a uniform martensitic structure throughout the MS1-P20 hybrid steels, leading to a less detectable interface under electron backscatter diffraction (EBSD) imaging. The mechanical performance of heat-treated hybrid steels was evaluated using complex loading conditions. 3-point and 4-point bending tests were performed to assess the impact of heat treatments on the mechanical performance of the hybrid steels. The heat-treated samples exhibited higher strength with relatively homogeneous hardness variations and deformed more uniformly in bending conditions.

In this work, the effect of heating rate on the phase transformation temperatures was investigated using dilatometry analysis. Continuous heating and isothermal holding above Ac₃ temperature on microstructural evolutions in additively manufactured (AM) parts of Fe-Cr-Ni maraging stainless steel were studied. The microstructural features developed within the heating processes were characterized employing electron backscatter diffraction and transmission electron microscopy. Austenite reversion was found to take place in two steps for the AM parts by a diffusive mechanism as well as the precipitation reactions. Although grain refinement occurred during the austenite reversion of the continuously heated samples, the microstructure showed a coarser grain size after isothermal heating. The crystallographic orientations developed after the heating processes were different from those of the initial ones implying the absence of the austenite memory effect.

Due to high local cooling rates and non-equilibrium directional solidification conditions, selective laser melting (SLM) processed metals exhibit microstructural and textural features significantly different from the conventionally processed ones. The evolution of crystallographic orientations in a maraging stainless steel (commercially known as stainless steel CX) sample fabricated by the SLM process was studied through experimental and modelling approaches Electron backscattering diffraction analysis showed that the dominant texture components in martensite and austenite phases are <111>|| building direction and <011>|| building direction, respectively. Texture simulation indicated that the formation of crystallographic orientations in the studied sample is the result of two consecutive phase transformations, from initially solidified delta ferrite phase with dominant cube fiber texture to austenite and austenite to martensite.

Characterization of the austenite phase at high temperatures is important for understanding the microstructural evolution during steel processing. The austenite phase structure can be reconstructed from the room-temperature microstructure employing the crystallographic orientation relationship between the parent and product phases. The actual orientation relationships in steels are often calculated on the basis of well known relations (e.g. Kurdjumov-Sachs), which may differ from the experimentally observed orientation relationships. This work introduces a new approach to improve the current state of the art in prior phase reconstruction. The proposed approach consists of two new algorithms that are sequentially applied on an electron backscatter diffraction (EBSD) measured data set of the product phase microstructure: (i) an automated identification of the optimum orientation relationship using the observed misorientation distribution of the entire EBSD scan and (ii) reconstruction of the parent phase microstructure using a random walk clustering technique. The latter identifies groups of closely related grains according to their angular deviation from the proposed orientation relationship. The results were validated by near in situ experimental observations of phase transformation in an Fe-Ni alloy whereby the experimentally measured parent phase structure could be compared point by point with the reconstructed counterpart.