Solidification microstructure and residual stress correlations in direct energy deposited type 316L stainless steel

Guo, Da; Yan, Kun; Callaghan, Mark; Daisenberger, Dominik; Chatterton, Mark; Chen, Jiadong; Wisbey, A.; Mirihanage, Wajira

doi:10.1016/j.matdes.2021.109782

Cited by 25 publications

(7 citation statements)

References 27 publications

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“…As they cool to the ductility dip temperature range, strain localization and an inherent reduction in ductility can precipitate cracking, as delineated in Zhang et al's study [81] examining cracking mechanisms in laser-melted Inconel 738 alloys (refer to Figure 5). Regarding the impetus for crack formation, based on the research by Guo et al [82] and Zhou et al [83], the genesis of cracking is closely correlated with residual stresses in additively manufactured components. Guo et al showed that tensile residual stresses can accelerate crack growth along the lamellar structure in 316L stainless steel produced by DED.…”

Section: Cracking Defectsmentioning

confidence: 99%

“…In turn, this approach helps minimize part distortion, lack of fusion defects, and the propensity for cracking in the fabricated component. Zhang et al [85] proposed an innovative in situ doping approach, whereby thin interlayers of Inconel 718 were deposited between Regarding the impetus for crack formation, based on the research by Guo et al [82] and Zhou et al [83], the genesis of cracking is closely correlated with residual stresses in additively manufactured components. Guo et al showed that tensile residual stresses can accelerate crack growth along the lamellar structure in 316L stainless steel produced by DED.…”

Section: Cracking Defectsmentioning

confidence: 99%

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Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Zhang,

Xu,

et al. 2024

Crystals

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Directed Energy Deposition (DED), a branch of AM processes, has emerged as a significant technique for fabricating large metal components in sectors such as aerospace, automotive, and healthcare. DED is characterized by its high deposition rate and scalability, which stand out among other AM processes. However, it encounters critical issues such as residual stresses, distortion, porosity, and rough surfaces resulting from rapid melting and solidification. As a novel advancement, Ultrasonic-Assisted Directed Energy Deposition (UA-DED) integrates ultrasonic oscillations into DED aimed at addressing these challenges. Herein, the latest research related to the UA-DED process and the current major challenges of the DED process, residual stresses, porosity, and crack defects are critically reviewed. Subsequently, the paper also details the working principle and system components of UA-DED technology and reviews the material improvement by introducing UA into the DED process, grain, porosity, tensile properties, and deposition defects. The most critical optimization methods of process parameter variables for UA and the different material interaction mechanisms between UA and DED processes are identified and discussed in detail. Finally, the perspectives on the research gap and potential future developments in UA-DED are also discussed.

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Section: Cracking Defectsmentioning

confidence: 99%

Section: Cracking Defectsmentioning

confidence: 99%

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Zhang,

Xu,

et al. 2024

Crystals

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“…Residual strain measurements of an as-deposited plate were carried out at beamline I15 of Diamond Light Source, UK and further details can be found in reference [4]. The built plate was oriented perpendicular to the incident X-ray beam.…”

Section: Methodsmentioning

confidence: 99%

The Mechanical Performance of Additively Manufactured 316L Austenitic Stainless Steel

Wisbey

Coon

Chatterton

et al. 2022

Volume 4A: Materials and Fabrication

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Additive manufacturing (AM) offers the potential for significantly reducing the time and cost of new nuclear components. This process may also permit unique design features, for example internal geometries. However, the limitations of the technology need to be better understood to enable implementation and accreditation. Here a “blown powder” and laser melting process, within a helium shielded environment, was used to fabricate austenitic stainless steel 316L walls of ∼2.4 mm thickness, with the deposition parameters minimizing the surface roughness. A key aim was to evaluate the effect of the as-deposited surface finish and the bulk material on the tensile and fatigue properties. In addition, the effect of material orientation was also considered to be important. Microstructural characterization demonstrated the complex nature of the grain morphology arising from the as-manufactured AM process, including elongated grains following the thermal gradients. However, areas of equiaxed grains were also observed at the sample surfaces. Si-Mn-O particles, up to ∼20 μm in diameter, were noted throughout the samples produced. Residual strains have also been measured and correlated with microstructural features. The tensile performance was generally similar to wrought 316L material but exhibited some anisotropy. The fatigue endurance of as-deposited AM 316L was significantly lower than wrought material. However, surface grinding of the AM 316L was shown to be beneficial. It was noted that in all cases examined, fatigue crack initiation was found to occur at the Si-Mn-O particles, in both surface finishes — clearly a performance limitation.

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“…However, the detailed in-situ information about interrelationship of molten metal flow and porosity formation are limited due to the instantaneity of fusion welding process and opacity of metallic materials, when conventional metallographic methods are used to observe the melt pools and weld joints. Synchrotron X-ray imaging has recently become an important way to study the dynamic processes, such as melting and solidification, in the welding and additive manufacturing of metallic alloys [10][11][12][13][14][15][16]. Notably, data collected from real-time X-ray experiments is critical for developing IOP Publishing doi:10.1088/1757-899X/1274/1/012011 2 physically accurate simulation models of dynamic melt pools [17,18].…”

Section: Introductionmentioning

confidence: 99%

Effects of melt pool flow on porosity levels in arc welding

Falch

Drakopoulos

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Arc welding is one of the widely used approaches for joining metals. During the arc welding process, an electric arc creates intense heat to fuse metals that forms the melt pool between the parts to be welded together. Intensive flow fields are observable within the fusion weld pools as a result of multiple driving forces. The flow patterns within the melt pool significantly determine the shape of the weld joint and other attributes of the solidified joint, such as microstructure and defects. Porosity is one of the solidification-related defects that can bring a detrimental impact. During the formation and solidification of weld pools, gas bubbles that are formed can be driven in or out from the pool by the flow. In this work, employing in situ synchrotron X-rays, we have observed how different flow conditions and air-liquid interface are contributed to retaining and releasing the gas bubbles that formed during the arc welding. The results suggest that underpinning driving forces, such as electromagnetic forces, act on molten metal to retain the pores inside the weld joints; but, gravity-driven effects can contribute to reduce the porosity, with appropriate process conditions.

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Solidification microstructure and residual stress correlations in direct energy deposited type 316L stainless steel

Cited by 25 publications

References 27 publications

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

Advances in Ultrasonic-Assisted Directed Energy Deposition (DED) for Metal Additive Manufacturing

The Mechanical Performance of Additively Manufactured 316L Austenitic Stainless Steel

Effects of melt pool flow on porosity levels in arc welding

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