Abstract
Wire arc additive manufacturing (WAAM) direct energy deposition is used to process two different Duplex Stainless-Steels (DSS) wire chemistries. Macro and micro mechanical response variables relevant to industrialization are studied using a Design of the Experiment (DoE) approach.
The tested window of operation (i.e., 0.09 kJ/mm ≥ Heat Input (HI) ≥ 0.23 kJ/mm – nominal value) show that variation of layer height and overthickness are highly correlated with travel speed and wire feed speed and positively correlated with heat input. The maximum achieved average instantaneous deposition rate is 3.54 kg/h. Besides, the wire chemistry G2205, with a decreased nickel content, shows a stable ferrite-to-austenite ratio of equal proportions (i.e., (Fe) ̅% = 49.20 ± 1.92 % and (HV) ̅3 = 252.8 ± 3.55), whereas G2209 provides a reduced ferrite content (i.e., (Fe) ̅% = 29.69 ± 0.56 % and (HV) ̅3 = 241.6 ± 3.17). Part geometry and weaving strategy affect the homogeneous distribution of Fe% distribution and high heat inputs lead to coarser microstructures with dendritic morphology.
The manufacturing weaving strategy creates local heterogeneous microstructure with varying Fe%. Thus, an understanding of this effect with higher-dimensional design spaces, uncertainty quantification, and dynamic process control are required to drive metal WAAM towards full industrialization.
The tested window of operation (i.e., 0.09 kJ/mm ≥ Heat Input (HI) ≥ 0.23 kJ/mm – nominal value) show that variation of layer height and overthickness are highly correlated with travel speed and wire feed speed and positively correlated with heat input. The maximum achieved average instantaneous deposition rate is 3.54 kg/h. Besides, the wire chemistry G2205, with a decreased nickel content, shows a stable ferrite-to-austenite ratio of equal proportions (i.e., (Fe) ̅% = 49.20 ± 1.92 % and (HV) ̅3 = 252.8 ± 3.55), whereas G2209 provides a reduced ferrite content (i.e., (Fe) ̅% = 29.69 ± 0.56 % and (HV) ̅3 = 241.6 ± 3.17). Part geometry and weaving strategy affect the homogeneous distribution of Fe% distribution and high heat inputs lead to coarser microstructures with dendritic morphology.
The manufacturing weaving strategy creates local heterogeneous microstructure with varying Fe%. Thus, an understanding of this effect with higher-dimensional design spaces, uncertainty quantification, and dynamic process control are required to drive metal WAAM towards full industrialization.
| Original language | English |
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| DOIs | |
| Publication status | Submitted - Nov 2022 |
| Publication type | Not Eligible |