Abstract Progressing towards circular economy requires smarter and more efficient use of energy and resources. Laser beam can be efficient and flexible tool for melting different metals, commonly used in cladding and additive manufacturing (AM) with a wire and powder feedstock. As an alternative, feedstock in the form of plates and sheets can be used for cladding to achieve corrosion resistant surfaces. Compared to powder or wire, plates are easier to process, less costly to use, and may come as scrap metal. This leads to smarter and more efficient resource utilization. However, processing plates in such way is not mature and requires more in-depth investigation to be competitive with well-established methods. In this work, 2.0 mm thick 316L stainless steel plates were remelted by a high-power fibre laser beam for cladding on carbon steel substrates. It was compared to the conventional cold metal transfer (CMT) welding-based arc cladding which is frequently used due to a low heat input. In the first phase, different defocusing distances were studied to understand the laser remelting process capabilities to optimize the productivity. It was found that a highly defocused laser beam provided unstable melt pool conditions with low track quality. Compared to CMT, the laser remelting provided enhanced productivity, reduced heat input by 50% per pass, and lower distortions. Microhardness testing showed an increase in hardness in the intermediate layer towards the fusion line due to carbon diffusion. Despite a higher delta ferrite formation in laser-remelted tracks, a comparable corrosion protection to CMT was observed. The proposed method is promising for reducing CO 2 emissions with respect to reusing scrap metal in the form of plates or use of ordinary plates instead of filler wires which opens possibilities for further enhancements.
Recent substantial studies indicate that high-entropy alloys (HEAs) possess superior mechanical performance, including exceptional strength, high creep resistance, etc. However, additive manufacturing (AM), a burgeoning manufacturing method, may induce extraordinary impacts on the resulting mechanical properties. For the additively manufactured (AM-ed) HEAs, the nanoscale mechanical performance and deformation mechanisms in accordance with the microstructural properties remain unclear. In this work, the microstructure and nanomechanical properties of an AM-ed (CrCoNiFe)94Ti2Al4 HEA were investigated. The local mechanical properties including hardness, elastic modulus, and nanoscale creep deformation, were explored by nanoindentation-based measurement. Simultaneously, the crystallographic orientation dependence on the mechanical behavior of AM-ed HEA was carried out by combining with electron backscattered diffraction (EBSD). It is found that the {101}-grain has the highest hardness and elastic modulus, whereas the creep resistance of {111}-grain is the greatest, with the indicators of the creep mechanism showing lattice diffusion is the dominant mechanism. Two different states of HEA, as-printed and heat-treated, were utilized to explore the effect of heat treatment. Heat treatment in the current study can increase the hardness and elastic modulus but decrease the creep resistance slightly. This work elucidates the underlying mechanisms of grain orientation dependence on nanomechanical properties and the effects of heat treatment. Moreover, it also sheds light on the particular creep behavior at the nanoscale and creep mechanism of the AM-ed (CrCoNiFe)94Ti2Al4 HEA.
The additive manufacturing (AM) process often results in non-uniform microstructure and different mechanical properties in sequential layers, impacting the overall performance of the AM-ed component. However, it is extremely challenging to evaluate the local stress-strain behavior of each individual layer, owing to the limited size of the AM-ed layered structure. To this end, a framework for characterizing and predicting the mechanical evolution of AM-ed multiphase alloys by combing nanoindentation and microstructure-based finite element method (FEM) was proposed. The sample used in this study was superduplex stainless steel (SDSS) manufactured by wire arc additive manufacturing (WAAM), and the microstructure varied from layer to layer. Firstly, the mechanical properties of the two constituent phases in each layer, including elastic modulus and hardness, were obtained by nanoindentation, and the indentation size effect (ISE) was also evaluated. The yield strength and hardening exponent of each phase were subsequently estimated by reverse analysis method, and therefore the constitutive behaviors of the individual phase, which served as input parameters for FEM, were acquired. By aid of real microstructure-based FEM under uniaxial tension, the overall stress-strain behaviors of each layer and the distributions of the stress and strain during the deformation process were investigated. This work provides a new avenue for the characterization of the multiphase alloys in AM industry, beneficial to the understanding of the mechanical evolution in AM-ed materials.
In the present study, the thermal program in wire and arc additive manufacturing has been varied in terms of heat input and interpass temperature. Three walls were completed with subsequent Charpy V impact toughness and crack-tip opening displacement fracture toughness, together with a detailed microstructure characterization using light microscopy and scanning and transmission electron microscopy. The results clearly demonstrate that the formation of sigma phase may deteriorate the toughness of superduplex components. Such formation may take place under prolonged cooling time, which may occur when subsequent passes are deposited with too high interpass temperatures. This transformation behavior may limit the productivity in additive manufacturing of such steels and care must be taken in selection of proper combination of arc energy and interpass temperature.
Deposition patterns can significantly influence the distribution and magnitude of residual stress in additively manufactured parts. Time-consuming thermal-mechanical simulations and costly experimental studies are often required to identify the optimal patterns. A simple and generic method to evaluate and optimize the deposition pattern for the purpose of minimizing residual stress is in urgent need. To overcome the shortcomings of the current practice, here we propose a novel pattern evaluation criterion. Starting from the discretization of the deposition pattern by a series of sequence numbers, we introduce two interconnected concepts. The first is called "equivalent bead sequence number" which can be physically interpreted as an index of the localized heat accumulation induced by the deposition process. Based on this point-wise "equivalent bead sequence number", the second concept called "bead sequence number dispersion index" which can be considered as a representation of the global heat accumulation gradient, is proposed as a criterion for assessing the resulting residual stress. The temperature fields and residual stresses of a square part with six typical deposition patterns predicted by thermo-mechanical finite element simulations are used to develop and verify the proposed criterion. It is found that the "equivalent bead sequence number" of a given pattern is closely correlated to the distribution of the associated temperature and residual stress. More interestingly, both the highest equivalent and highest maximum principal residual stress of a pattern linearly increase with its corresponding value of "bead sequence number dispersion index". Guided by this relation, two new patterns with lower residual stress are developed and evaluated. Among all the patterns considered, the so-called S pattern shows the lowest value of the "bead sequence number dispersion index" which corresponds to the lowest residual stress. The proposed sequence-driven approach provides a new candidate for real-time evaluation and optimization of the deposition pattern in additive manufacturing.
Abstract For metallic materials, standard uniaxial tensile tests with round bar specimens or flat specimens only provide accurate equivalent stress–strain curve before diffuse necking. However, for numerical modelling of problems where very large strains occur, such as plastic forming and ductile damage and fracture, understanding the post‐necking strain hardening behaviour is necessary. Also, welding is a highly complex metallurgical process, and therefore, weldments are susceptible to material discontinuities, flaws, and residual stresses. It becomes even more important to characterize the equivalent stress–strain curve in large strains of each material zone in weldments properly for structural integrity assessment. The aim of this paper is to provide a state‐of‐the‐art review on quasi‐static standard tensile test for stress–strain curves measurement of metallic materials. Meanwhile, methods available in literature for characterization of the equivalent stress–strain curve in the post‐necking regime are introduced. Novel methods with axisymmetric notched round bar specimens for accurately capturing the equivalent stress–strain curve of each material zone in weldment are presented as well. Advantages and limitations of these methods are briefly discussed.
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