A Metallurgical Investigation of the Direct Energy Deposition Surface Repair of Ferrous Alloys

Abstract

Among additive manufacturing (AM) processes, the direct energy deposition (DED) by laser is explored to establish its applicability for the repair of ferrous alloys such as UNS G41400 low-alloy steel, UNS S41000 martensitic stainless steel, UNS S17400 precipitation-strengthened martensitic stainless steel, and UNS S32750 super-duplex stainless steel. Unlike plating, thermal spray, and conventional cladding weld, DED laser powder deposition offers potential advantages, e.g., thin deposits, limited dilutions, narrow heat-affected zones (HAZ), potentially improved surface properties. In this investigation, all AM deposits were completed with an IREPA CLAD™ system using a powder feed of UNS N06625, an alloy largely selected for its outstanding corrosion resistance. This investigation first addresses topological aspects of AM deposits (including visual imperfections) before focusing on changes in microstructure, microhardness, chemical composition across AM deposits and base materials. It has been established that dense, uniform, hard (~ 300 HVN), crack-free UNS N06625-compliant AM deposits of fine dendritic microstructures are reliably produced. However, except for the UNS S32750 steel, a significant martensitic hardening was observed in the HAZs of UNS G41400 (~ 650 HVN), UNS S41000 (~ 500 HVN), and UNS S17400 (~ 370 HVN). In summary, this investigation demonstrates that the DED laser repair of ferrous parts with UNS N06625 may restore damaged surfaces, but it also calls for cautions and complementary investigations for alloys experiencing a high HAZ hardening, for which industry standard recommendations are exceeded and lead to an increased risk of delayed cracking in corrosive environments.