Resistance Spot Welding of Additively Manufactured Maraging Steels—Part I: Nugget Formation

Abstract

Abstract Application of additively manufactured steels is unavoidably involved in the resistance spot welding with conventionally manufactured steels. However, the microstructural evolution of an additive manufactured steel at high temperatures is still unknown, especially for the rapid solidification process. This paper investigated the microstructural evolution of a selective laser melted maraging steel during the rapid solidification process via resistance spot welding. Asymmetrical fusion zone with boat shape was found in the spot weld due to the rougher surface and larger electrical resistance of maraging steel via selective laser melting (SLM) process. The rapid expansion of fusion zone at end of welding process was caused by the carbide formation at the heat-affected zone of maraging steel via selective laser melting process. Besides, printing orientation affected the surface roughness of a selective laser melted maraging steel and subsequently significantly influenced the early stage of formation of fusion zone of additively manufactured maraging steel. We expect that our findings will pave the way to the future application of additively manufactured steels in the industries.