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Wire arc additive manufacturing (WAAM) presents a highly promising alternative to conventional subtractive manufacturing methods to produce metallic components, particularly in the aerospace industry, where there is a demand for 17–4 precipitation-hardened (PH) stainless steel structures. This study focuses on investigating the microstructural characteristics, showing microhardness evaluations, and analyzing the tensile properties of the as-printed parts during the 17–4 PH manufacturing process at different locations and directions. The fabrication is carried out using gas metal wire arc additive manufacturing (GM-WAAM). As a result, it was found that the microstructure of the as-deposited part showed a complex configuration consisting of both finely equiaxed and coarsely formed δ-ferrite phases with vermicular and lathy morphologies. These phases were dispersed inside the martensitic matrix, while a small amount of retained austenite was also present. It was observed that the volume fraction of retained austenite (20–5%) and δ-ferrite phases (15.5–2.5%) decreased gradually from the bottom to the top of the as-deposited wall. This reduction in the fractions of these phases resulted in a progressive increase in both hardness (∼37%) and ultimate tensile strength (UTS) along the building direction. This study successfully fabricates a high-strength and ductile 17–4 PH as-printed part using WAAM. The findings provide evidence supporting the feasibility of employing WAAM for producing defect-free, high-strength components on a large scale while maintaining mechanical properties similar or better than wrought alloy 17–4 PH. 

In binder jetting, shrinkage and deformation occur during the sintering step, both of which are affected by the green density of the binder jetted materials. The study innovatively introduces a cost-effective, practical, and in-process monitoring system for visualizing shrinkage and deformation on larger samples than conventionally observed using small-scale specimens in dillatometry equipment. The powder characteristics and binder jet printing process itself influence the initial green density. The comprehensive analysis of powder flowability and packing density, densification behavior, and shrinkage reveals that the consolidated parts using virgin powder (with a green density of 55%) can achieve a relative density above 99.9% with an anisotropic shrinkage in the Z>X>Y direction. In contrast, the used or recycled powder exhibits a lower green density of ∼48%, higher shrinkage rate in all three dimensions, and a decreased degree of anisotropy. Using in-process imaging and experimental data on the grain size attained through optical microscopy and electron backscatered diffraction imaging, the material's shear and bulk viscosities were determined. The formation of delta-ferrite and its impact on densification were discussed in the context of solid-state and supersolidus liquid phase sintering. The model relied on the continuum sintering theory formulated by Skorohod and Olevsky. The strain evolution from the in-situ imaging of sintering process is correlated with porosity based on the used feedstock and applied sintering temperatures. The outcomes of this study offer valuable perspectives on anisotropic sintering mechanisms, bridging the knowledge gap regarding the relationships between structures produced through binder jetting and subsequent sintering of materials. 

Gas metal arc additive manufacturing (GMA-AM), also known as wire arc additive manufacturing (WAAM), uses an electric arc to melt a wire electrode and deposit objects layer by layer. This study focuses on creating single-pass wall structures using a low-carbon steel wire (ER70S-6) and examining the relationship between pulse frequency and weld geometry, microstructure, and mechanical properties. Microscopic observations showed a typical columnar microstructure with three distinct regions: acicular ferrite, bainite, and allotriomorphic ferrite in the first and last layers, while the mid-region exhibited homogenous polygonal ferrite grains with some pearlite at the grain boundaries. The tensile test results demonstrated a dependency of strength on the applied pulse frequency, with the highest strength (i.e., the ultimate tensile strength of 522 MPa and yield strength of 375 MPa with ductility of ∼52%) achieved in parts processed at a frequency of 100 Hz. Vickers microhardness values revealed uniform hardness in the middle region, consistent with the microstructure observation. Analyzing thermal cycles, coupled with microstructure analysis and continuous cooling transition diagrams, provided insight into how phase and microstructure evolution occurred in low-carbon low-alloy steels processed through PGMA-AM.