This study investigates a compact tensile-specimen geometry with enlarged, shoulder-mounted gripping heads for 17-4 PH stainless steel produced by Atomic Diffusion Additive Manufacturing (ADAM). The geometry was designed to reduce material consumption while providing stable gripping and promoting fracture localization within the gauge section. Specimens with a 20 mm gauge length and 6 mm gauge diameter were manufactured horizontally using a Markforged Metal X system and subsequently debound and sintered. Tensile testing was performed based on ASTM E8/E8M using three specimens. All specimens fractured within the gauge section without slippage or grip-related failure. The mean ultimate tensile strength was 1194.22 ± 4.53 MPa, the mean 0.2% proof strength was 837.49 ± 4.24 MPa, and the mean elongation at fracture was 2.96 ± 0.34%. Fractographic analysis revealed predominantly planar fracture surfaces, inter-bead voids, and interlayer discontinuities, while ductile dimple morphology was observed at the microscale. The results indicate that the proposed geometry provided stable gripping and consistent fracture localization under the investigated conditions and may represent a practical compact specimen-design approach for tensile testing of ADAM-produced metallic materials.

Atomic Diffusion Additive Manufacturing, 17-4 PH stainless steel, Tensile testing, Specimen geometry, Fractography

[1] Y. Zhang, L. Wu, X. Guo, S. Kane, Y. Deng, Y.-G. Jung, J.-H. Lee, J. Zhang, Additive manufacturing of metallic materials: A review. Journal of Materials Engineering and Performance, 27, 2018: 1–13. https://doi.org/10.1007/s11665-017-2747-y
[2] H. Bikas, P. Stavropoulos, G. Chryssolouris, Additive manufacturing methods and modelling approaches: A critical review. The International Journal of Advanced Manufacturing Technology, 83, 2016: 389–405. https://doi.org/10.1007/s00170-015-7576-2
[3] T. DebRoy, H.L. Wei, J.S. Zuback, T. Mukherjee, J.W. Elmer, J.O. Milewski, A.M. Beese, A. Wilson-Heid, A. De, W. Zhang, Additive manufacturing of metallic components – Process, structure and properties. Progress in Materials Science, 92, 2018: 112–224. https://doi.org/10.1016/j.pmatsci.2017.10.001
[4] Y. Kok, X.P. Tan, P. Wang, M.L.S. Nai, N.H. Loh, E. Liu, S.B. Tor, Anisotropy and heterogeneity of microstructure and mechanical properties in metal additive manufacturing: A critical review. Materials & Design, 139, 2018: 565–586. https://doi.org/10.1016/j.matdes.2017.11.021
[5] M. Galati, P. Minetola, Analysis of density, roughness, and accuracy of the atomic diffusion additive manufacturing (ADAM) process for metal parts. Materials, 12(24), 2019: 4122.
https://doi.org/10.3390/ma12244122
[6] K. Rane, M. Strano, A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts. Advances in Manufacturing, 7, 2019: 155–173. https://doi.org/10.1007/s40436-019-00253-6
[7] T.C. Henry, M.A. Morales, D.P. Cole, C.M. Shumeyko, J.C. Riddick, Mechanical behavior of 17-4 PH stainless steel processed by atomic diffusion additive manufacturing. The International Journal of Advanced Manufacturing Technology, 114, 2021: 2103–2114. https://doi.org/10.1007/s00170-021-06785-1
[8] T. Alkindi, M. Alyammahi, R.A. Susantyoko, S. Atatreh, The effect of varying specimens’ printing angles to the bed surface on the tensile strength of 3D-printed 17-4PH stainless-steels via metal FFF additive manufacturing. MRS Communications, 11, 2021: 310–316. https://doi.org/10.1557/s43579-021-00040-0
[9] A.D. Akessa, W.M. Tucho, H.G. Lemu, J. Grønsund, Investigations of the microstructure and mechanical properties of 17-4 PH ss printed using a Markforged Metal X. Materials, 15(19), 2022: 6898. https://doi.org/10.3390/ma15196898
[10] J. Rodríguez, A. Zuriarrain, A. Madariaga, P.J. Arrazola, E. Dominguez, I. Fraile, D. Soler, Mechanical properties and fatigue performance of 17-4 PH stainless steel manufactured by atomic diffusion additive manufacturing technology. Journal of Manufacturing and Materials Processing, 7(5), 2023: 172. https://doi.org/10.3390/jmmp7050172
[11] T.T. Opoz, A. Burgess, J.I. Ahuir-Torres, H.R. Kotadia, S. Tammas-Williams, The effect of surface finish and post-processing on mechanical properties of 17-4 PH stainless steel produced by the atomic diffusion additive manufacturing process (ADAM). The International Journal of Advanced Manufacturing Technology, 130, 2024: 4053–4066. https://doi.org/10.1007/s00170-024-12949-6
[12] ASTM E8/E8M-25: Standard Test Methods for Tension Testing of Metallic Materials. ASTM International, West Conshohocken, Pennsylvania, USA, 2025. https://doi.org/10.1520/E0008_E0008M-25
[13] G. Shanbhag, E. Wheat, S.P. Moylan, M. Vlasea, Effect of specimen geometry and orientation on tensile properties of Ti-6Al-4V manufactured by electron beam powder bed fusion. Additive Manufacturing, 48, 2021: 102366. https://doi.org/10.1016/j.addma.2021.102366
[14] L. Fu, M. Schiralli, M. Vedani, J. Olofsson, M. Górny, P. Govahi, R. Donnini, M. Losurdo, G. Angella, Effects of tensile specimen geometry and gripping system on the mechanical stability of ausferrite in austempered ductile irons. Materials, 18(18), 2025: 4359. https://doi.org/10.3390/ma18184359
[15] S.J. Park, J.E. Lee, S.C. Jin, N.K. Lee, K. Choi, S.H. Park, Y. Son, Tensile test of additively manufactured specimens with external notch removed via laser cutting in material extrusion. Polymer Testing, 110, 2022: 107581. https://doi.org/10.1016/j.polymertesting.2022.107581
[16] Material datasheet – 17-4 PH Stainless Steel Technical Datasheet. Markforged Inc., Watertown, Massachusetts, USA, 2026. https://static.markforged.com/downloads/markforged_datasheet_17-4_ph_stainless_steel.pdf (Accessed: 18 July 2026).
[17] D. Gonzalez-Nino, S. Sonntag, M. Afshar-Mohajer, J. Goss, M. Zou, G.S. Prinz, Micromechanical tension testing of additively manufactured 17-4 PH stainless steel specimens. Journal of Visualized Experiments, 170, 2021: e62433. https://doi.org/10.3791/62433
[18] K. Jasik, L. Śnieżek, J. Kluczyński, J. Łuszczek, K. Grzelak, B. Sarzyński, I. Szachogłuchowicz, 17-4 PH Steel Parts Obtained through MEX and PBF-LB/M Technologies: Comparison of the Structural Properties. Materials, 17(12), 2024: 2801. https://doi.org/10.3390/ma17122801
[19] J. Gonzalez-Gutierrez, F. Arbeiter, T. Schlauf, C. Kukla, C. Holzer, Tensile properties of sintered 17-4PH stainless steel fabricated by material extrusion additive manufacturing. Materials Letters, 248, 2019: 165–168. https://doi.org/10.1016/j.matlet.2019.04.024
[20] M. Naim, M. Chemkhi, J. Kauffmann, A. Alhussein, Taguchi DoE analysis and characterization of 17-4 PH stainless steel parts produced by material extrusion (MEX) process. Advances in Industrial and Manufacturing Engineering, 8, 2024: 100138. https://doi.org/10.1016/j.aime.2024.100138
[21] Y.-H. Cho, S.-Y. Park, J.-Y. Kim, K.-A. Lee, 17-4PH stainless steel with excellent strength–elongation combination developed via material extrusion additive manufacturing. Journal of Materials Research and Technology, 24, 2023: 3284–3299. https://doi.org/10.1016/j.jmrt.2023.03.228
[22] A. Romero, M.A. Caminero, E. García-Plaza, P.J. Núñez, J.M. Chacón, G.P. Rodríguez, A. Cañadilla, J.L. Martínez, Mechanical and metrological characterisation of 17-4PH stainless steel structures processed by material extrusion additive manufacturing. Journal of Materials Research and Technology, 38, 2025: 1699–1716. https://doi.org/10.1016/j.jmrt.2025.08.027
[23] C. Gong, J.M. Djouda, A. Hmima, F. Gaslain, J. Kauffmann, M. Chemkhi, T. Maurer, B. Panicaud, Local characterization of stainless steel 17-4PH produced by material extrusion additive manufacturing: Influence of the post-treatment. Materials Science and Engineering: A, 880, 2023: 145371.
https://doi.org/10.1016/j.msea.2023.145371
[24] A. Sakkaeo, C. Suwanpreecha, P. Newyawong, V. Yordsri, S. Songkuea, T. Wutikhun, A. Manonukul, Post-processing of material extrusion additively manufactured 17-4PH stainless steel via aging and multi-step shot peening: surface integrity and wear response. Wear, 584–585, 2025: 206383.
https://doi.org/10.1016/j.wear.2025.206383
[25] G. Ledniczky, M. Sárközi, I. Zsoldos, Z. Weltsch, Defect evolution and mechanical performance of fused filament fabrication-manufactured 17-4PH stainless steel revealed by X-ray computed tomography. Advanced Engineering Materials, 28(16), 2026: e71034.
https://doi.org/10.1002/adem.71034