Additive Manufacturing with Superduplex Stainless Steel Wire by CMT Process

Abstract

For many years, the oil and gas industry has utilized superduplex stainless steels due to their high strength and excellent corrosion resistance. Wire arc additive manufacturing (WAAM) was used with superduplex filler wire to create walls with different heat input. Due to the multiple heating and cooling cycles during layer deposition, brittle secondary phases may form such as intermetallic sigma (σ) phase. By inspecting deposited walls within wide range of heat inputs (0.40–0.87 kJ/mm), no intermetallic phases formed due to low inter-pass temperatures used, together with the high Ni content in the applied wire. Lower mechanical properties were observed with high heat inputs due to low ferrite volume fraction, precipitation of Cr nitrides and formation of secondary austenite. The walls showed good toughness values based on both Charpy V-notch and CTOD (crack tip opening displacement) testing.

Preliminary Process and Microstructure Examination of Flux-Cored Wire Arc Additive Manufactured 18Ni-12Co-4Mo-Ti Maraging Steel

“…Austenitic stainless steels also qualify as trouble-free materials, which is proved by Xie et al [9], Yao et al [22] and Wu et al [23]. Roy et al [2] successfully made a part of AISI 410 martensitic stainless steel; similarly, Lervåg et al [10] for superduplex steel and Tain et al [31] for 10CrNi3MoV steel.…”

“…WAAM offers lower maintenance costs and a higher deposition rate (up to 7-10 kg/h) than other AM processes [2,3]. Both new ways of conducting the process [4][5][6][7][8][9][10], strategies [11,12], and the use of new filler materials are investigated. WAAM parameters have a significant influence on the geometry and microstructure, which was studied by Dinovitzer et al [13].…”

Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire

“…Hence, the applications of wire-feed DED can be found in the aerospace industry, e.g., mount rings for entire fan cases [3] and features of compressor casings [4] of turbo jet engines as well as space rocket nozzles [5]. Thus, an increased interest in the use of the wire-feed DED for processing of high temperature and corrosion resistant metals, like stainless steels [6][7][8], Nickel [8][9][10][11] and Titanium-based [12,13] alloys, is being observed.…”

Microstructure of laser metal deposited duplex stainless steel: Influence of shielding gas and heat treatment

“…The authors evaluated the residual stress distribution in that functionally graded material [13]. In the last 2 years there has been a boost in publications related to the study of duplex stainless steels deposited when using AM processes that use electric arc as the power source and wire as a feedstock, commonly designated as Wire Arc Additive Manufacturing (WAAM) [14][15][16][17][18][19][20][21].…”