PSI - Issue 77

ScienceDirect Structural Integrity Procedia 00 (2026) 000–000 Structural Integrity Procedia 00 (2026) 000–000 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

Procedia Structural Integrity 77 (2026) 537–542

© 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers Abstract Fatigue crack initiation and propagation are critical in determining fatigue life, as they are significantly affected by surface roughness, microstructural parameters (such as dislocation density, crystallite size, and microcracks), and especially by macroscopic residual stresses. During additive manufacturing via selective laser melting, a complex distribution of residual stresses is introduced, which can substantially affect both the printing process and the mechanical behaviour of the final component. In some cases, the magnitude of these stresses can approach the yield strength of the material. Consequently, research has focused on optimizing 3D printing parameters to minimize RS in maraging steel. The macroscopic residual stress profile, obtained through X ray diffraction combined with gradual electrolytic removal of surface layers, was analysed and compared with mechanical properties, particularly fatigue life. Samples were subjected to high cycle fatigue testing to investigate the influence of various factors on fatigue performance. It has been demonstrated that fatigue life is influenced not only by residual stresses at the surface but also by those present in the near-surface layers, highlighting the importance of stress distribution in fatigue performance. © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers Keywords: Selective laser melting; printing parameters, residual stresses, X-ray diffraction, high cycle fatigue testing Abstract Fatigue crack initiation and propagation are critical in determining fatigue life, as they are significantly affected by surface roughness, microstructural parameters (such as dislocation density, crystallite size, and microcracks), and especially by macroscopic residual stresses. During additive manufacturing via selective laser melting, a complex distribution of residual stresses is introduced, which can substantially affect both the printing process and the mechanical behaviour of the final component. In some cases, the magnitude of these stresses can approach the yield strength of the material. Consequently, research has focused on optimizing 3D printing parameters to minimize RS in maraging steel. The macroscopic residual stress profile, obtained through X ray diffraction combined with gradual electrolytic removal of surface layers, was analysed and compared with mechanical properties, particularly fatigue life. Samples were subjected to high cycle fatigue testing to investigate the influence of various factors on fatigue performance. It has been demonstrated that fatigue life is influenced not only by residual stresses at the surface but also by those present in the near-surface layers, highlighting the importance of stress distribution in fatigue performance. © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers Keywords: Selective laser melting; printing parameters, residual stresses, X-ray diffraction, high cycle fatigue testing International Conference on Structural Integrity Optimization of 3D printing parameters to minimize residual stresses in maraging steel Karel Trojan a *, Ivana Zetková b , Jiří Čapek a , Tomáš Bakša b , Kateřina Aubrechtová Dragounová a , Nikolaj Ganev a , Miloslav Kepka jr. b , Luboš Rozkošný c a Faculty of Nuclear Sciences and Physical Engineering, Czech Technical University in Prague, Trojanova 13, 120 00 Prague, Czech Republic b Regional Technological Institute, Faculty of Mechanical Engineering, University of West Bohemia, Univerzitní 8, 306 14 Pilsen, Czech Republic c Innomia a.s., Národní 980, 551 01 Jaroměř , Czech Republic International Conference on Structural Integrity Optimization of 3D printing parameters to minimize residual stresses in maraging steel Karel Trojan a *, Ivana Zetková b , Jiří Čapek a , Tomáš Bakša b , Kateřina Aubrechtová Dragounová a , Nikolaj Ganev a , Miloslav Kepka jr. b , Luboš Rozkošný c a Faculty of Nuclear Sciences and Physical Engineering, Czech Technical University in Prague, Trojanova 13, 120 00 Prague, Czech Republic b Regional Technological Institute, Faculty of Mechanical Engineering, University of West Bohemia, Univerzitní 8, 306 14 Pilsen, Czech Republic c Innomia a.s., Národní 980, 551 01 Jaroměř , Czech Republic

* Corresponding author. Tel.: +420-778-529-853. E-mail address: karel.trojan@fjfi.cvut.cz * Corresponding author. Tel.: +420-778-529-853. E-mail address: karel.trojan@fjfi.cvut.cz

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 10.1016/j.prostr.2026.01.067