The process parameters of selective laser melting (SLM) fabricated 24CrNiMoY alloy steel were optimised. Different contents of zirconia powder were added to the 24CrNiMoY alloy steel powder. With the optimum process parameters, the fabricated samples were characterised using various modern analysis methods. The results show that the main phase composition of 24CrNiMoY alloy steel is proecctectoid ferrite (PF) and granular bainite (GB). After the addition of zirconia, Lath bainite (LB) begins to appear, and with the increase of zirconia, the content of LB first increases and then decreases. When the zirconia content is 0.3%, the average micro hardness of the 24CrNiMoY alloy steel reaches the maximum and is 374 HV. In addition, the tensile strength is 811 MPa, the elongation is 6.7%, and the fracture surface shows ductile fracture.
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