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In this study, the deposition of martensitic stainless-steel (Metco 42C) powder on 42CrMo4 structural steel by direct laser deposition (DLD) was investigated. Clads were produced by varying the laser power, scanning speed, feed rate, and preheating. The effect of these processing variables on the microstructure and microhardness of the clads was analyzed, as well as their soundness, yield (measured by dilution), and geometric characteristics (height, width, and depth). The complex interaction of the evaluated processing variables forced the application of complex parameters to systematize their effect on the clads. A genetic optimization algorithm was performed to determine the processing conditions warranting high-quality clads, that is, sound clads, metallurgically bonded to the substrate with required deposition yield.

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The present contribution addresses the micromechanical and thermal analysis of directed energy deposition-manufactured, stainless steel 316L components by utilizing experimental and numerical analyses. It has been established that a combination of controlling process parameters, manufacturing environment and microstructural anisotropies could adversely affect the quality of as-deposited parts. Among other factors, the shape, size, and distribution of the microvoids and porosities could, to some extent, have deteriorating effects on the mechanical properties of the additively manufactured components. In this work, the micromechanically motivated Gurson–Tvergaard–Needleman damage model is utilized and the performance of the model is evaluated by observing the damage accumulation in the loaded additively manufactured specimens. By relying to the laboratory-based material data and fractographic imagery from nonstandard tensile testing on fabricated samples in different building directions, numerical model predictions are found to be in a good agreement with the experimental observations. Furthermore, by resorting to the finite element software capabilities, the thermal analyses are carried out on the manufactured cube component and the influence of the process parameters on the temperature distribution is revealed.

Experimental and numerical study regarding the uniaxial tensile test and the forming limit diagram are addressed in this paper for AL2024 with the face-centered cube structure. First, representation of a grain structure can be obtained directly by mapping metallographic observations via scanning electron microscopy approach. Artificial grain microstructures produced by Voronoi Tessellation method are employed in the model using VGRAIN software. By resorting to the finite element software (ABAQUS) capabilities, the constitutive equations of the crystal plasticity were utilized and implemented as a user subroutine material UMAT code. The hardening parameters were calibrated by a trial and error approach in order to fit experimental tensile results with the simulation. Then the effect of the changing grain size, the heterogeneity factor, and the grain aspect ratio were studied for a uniaxial tensile test to emphasize the importance of the microstudy behavior of grains in material behavior. Furthermore, the polycrystal plasticity grain distribution was employed in the Nakazima test in order to obtain the forming limit diagram. The crystal plasticity-driven forming limit diagram reveals more accurate strains, taking into account the involving the micromechanical features of the grains. An innovative approach is pursued in this study to discover the necking angle, both in tensile test or Nakazima samples, showing a good agreement with the experiment results.

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Additive manufacturing (AM) of metals proved to be beneficial in many industrial and non-industrial areas due to its low material waste and fast stacking speed to fabricate high performance products. The present contribution addresses several known challenges including mechanical behaviour and porosity analysis on directed energy deposition (DED) manufactured stainless steel 316L components. The experimental methodology consisting of metal deposition procedure, hardness testing and fractographic observations on manufactured mini-tensile test samples is described. A ductile fracture material model based on the Rousselier damage criterion is utilized within a FE framework for evaluation of material global response and determination of initial porosity value representing the structure’s nucleating void population. Alternatively, the initial pore sizes are characterized using the generalized mixture rule (GMR) analysis and the validity of the approach is examined against the experimental results.