Recyclability of stainless steel (316 L) powder within the additive manufacturing process

Gorji, Nima E.; O’Connor, Robert; Mussatto, Andre; Snelgrove, Matthew; Mani-González, P.G.; Brabazon, Dermot

doi:10.1016/j.mtla.2019.100489

Cited by 60 publications

(26 citation statements)

References 19 publications

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“…Typically, DED/LENS employs high power heating source (electrons/ laser) in the kilowatts power range, whereas LPBF uses lasers in the range of few hundred watts 11,19,30 . The DED/ LENS processes where a mix of powders are blown on the melt pool, powder recyclability is nearly impossible, whereas the LPBF has near complete recyclability of the unmelted feedstock powder due to very localized melting and lower powder contamination 31,32 .…”

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confidence: 99%

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Murkute

Pasebani

Isgor

2020

Sci Rep

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this study aims to improve the corrosion resistance of the low carbon steel by cladding it with super duplex stainless steel using laser powder bed fusion process. critical process parameters such as laser power, laser scan speed, hatch spacing, and powder layer thickness were optimized to achieve the best possible metallurgical bonding between the clad and the substrate. the evaporative losses experienced during the laser melting process resulted in clad layers with lower chromium content (12-25 wt. %) as compared to 26 wt. % of the feedstock powder. A clad thickness of 65.8 µm was achieved after melting ten 50 µm thick powder layers. the higher cooling rates associated with laser powder bed fusion resulted in fine high aspect ratio columnar grain structures with predominantly ferrite grains; however, widmanstätten austenite needles were observed with increasing laser scan speeds. increasing scan speed had a negative impact on the thickness, corrosion resistance, and the pitting potential of the clads exposed to 3.5 wt.% NaCl aqueous solution. Clads produced at the lowest scan speeds showed comparable corrosion resistance to rolled and annealed super duplex stainless steel. Duplex stainless steels (DSS) are a special class of ferrous alloys with a balanced ferrite (δ) and austenite (γ) phase microstructure. This dual-phase structure imparts these steels a high strength, toughness, and increased corrosion resistance in environments containing acids, acid chlorides, seawater, and caustic chemicals. Super duplex stainless steels (SDSS) 1 are a variant of DSS with higher Cr (25-26 wt. %) and Mo (4 wt. %) contents. SDSS typically shows superior pitting and stress corrosion cracking resistance than DSS; therefore, the use of SDSS has been increasing in highly corrosive environments, including oil and gas infrastructure, desalination plants, chemical storage tanks, heat exchangers, and paper/pulp manufacturing facilities 1. Although low carbon steel (LCS) remains to be the most widely used ferrous alloy, its applications are limited because it is highly vulnerable to corrosion in neutral, acidic, or saline environments 2. Corrosion-resistant SDSS alloys possess superior corrosion resistance than the LCS for the aforementioned applications, albeit with a significantly higher material cost. One of the viable means to reduce the component cost without compromising on service life is to manufacture a composite with a low-cost tough and ductile substrate cladded with a wear and corrosion resistant surface, as in the case of SDSS clads on an LCS substrate. These dissimilar metal composites (cladded systems) have been produced in the past using conventional manufacturing techniques such as welding 3-5 , diffusion bonding 6 , powder roll bonding 7 , hot rolling 8 , and reduction bonding 9. However, conventionally manufactured composites are often unfit for field use due to substandard clad-substrate bonding, often leading to clad delamination when subjected to operational stresses in the field. This substandard bond typically ...

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confidence: 99%

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Murkute

Pasebani

Isgor

2020

Sci Rep

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“…At a temperature of 400 °C, a significant reduction in hardness can be expected. Temperatures above 1100 °C are not considered due to carbide dissolution [17]. As previous investigations showed, plastic deformations for jet pressures below 0.7 bar can no longer or only with difficulty be determined [18], thus the minimum jet pressure of the current investigation was set at 1 bar.…”

Section: Evaluation and Discussion Of Descriptorsmentioning

confidence: 99%

“…The newly established particle-oriented peening setup used in this paper aims at the investigation of mechanical properties of individual particles, after a high velocity impact. This offers the advantage that in contrast to nanoindentation [17], no polished surface is required and greater deformation takes place, which is more robust against micro-influences. It allows for quick deformation of a large number of particles in a highly defined and reproducible way.…”

Section: High-throughput Methods and Materialsmentioning

confidence: 99%

Parameter Optimization in High-Throughput Testing for Structural Materials

et al. 2019

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High-throughput screenings are established evaluation methods in the development of functional materials and pharmaceutical active ingredients. The transfer of this approach to the development of structural materials requires extensive adaptations. In addition to the investigation of new test procedures for the determination of material properties and the treatment of metallic materials, the design of experiments is a research focus. Based on given descriptor target values, the statistical design of experiments determines investigations and treatments for the investigation of these materials. In this context, process parameters also have to be determined, as these have a major influence on the later material properties, especially during the treatment of samples. In this article, a method is presented which determines the process parameters iteratively. The validation of the calculated process parameters takes place based on differential scanning calorimetry used as the furnace for the heat treatment of small batches and particle-oriented peening as the characterization method.

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“…At the process stage, optimized technical changes are required to reduce energy and resource usage, hazardous wastes, workplace hazards, etc., to enhance product life by controlling process-induced surface integrity. For example, recycling of metal powder in metal additive manufacturing processes can optimize the resource consumption in three-dimensional (3D) printing technology [36,37]. Sustainable manufacturing can be accomplished by more energy-efficient technologies.…”

Section: Sustainable Manufacturingmentioning

confidence: 99%

Sustainability Assessment for Manufacturing Operations

et al. 2020

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Sustainability is becoming more and more important as a decision attribute in the manufacturing environment. However, quantitative metrics for all the aspects of the triple bottom line are difficult to assess. Within the present paper, the sustainability metrics are considered in tandem with other traditional manufacturing metrics such as time, flexibility, and quality and a novel framework is presented that integrates information and requirements from Computer-Aided Technologies (CAx) systems. A novel tool is outlined for considering a number of key performance indicators related to the triple bottom line when deciding the most appropriate process route. The implemented system allows the assessment of alternative process plans considering the market demands and available resources.

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Recyclability of stainless steel (316 L) powder within the additive manufacturing process

Cited by 60 publications

References 19 publications

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Parameter Optimization in High-Throughput Testing for Structural Materials

Sustainability Assessment for Manufacturing Operations

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Recyclability of stainless steel (316 L) powder within the additive manufacturing process

Cited by 60 publications

References 19 publications

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Metallurgical and Electrochemical Properties of Super Duplex Stainless Steel Clads on Low Carbon Steel Substrate produced with Laser Powder Bed Fusion

Parameter Optimization in High-Throughput Testing for Structural Materials

Sustainability Assessment for Manufacturing Operations

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Product

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Recyclability of stainless steel (316 L) powder within the additive manufacturing process