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.
Highlights
Additive manufacturing (AM) technologies, commonly known as 3D printing, have been the subject of significant progress over the past decade; a comprehensive review of the process is made by DebRoy et al [1]
The average layer height for the three different walls was 2.4, 2.8 and 3.4 mm for samples 1–3, respectively, which is consistent with the heat input variation
Neither pores nor cracking were visible, which means that the employed parameters are appropriate for production of AM walls
Summary
Additive manufacturing (AM) technologies, commonly known as 3D printing, have been the subject of significant progress over the past decade; a comprehensive review of the process is made by DebRoy et al [1]. AM is based on depositing single layers on the previous layers forming a complex shape with high efficiency of material utilization compared to subtractive processes such as milling. Previous layers are re-heated experiencing multiple liquid-solid and solid-state phase transformations. A widely used powder bed fusion (PBF) or selective laser sintering (SLS) process, where the laser or electron beam equipment is typically applied as the power source [2], may create any shape of complexity but more restricted to prototyping since the process is very slow. Wire arc additive manufacturing (WAAM) is a type of direct metal deposition (DMD) process, which utilizes filler wire and arc as heating source, enabling much higher productivity. Some limitation exists such as low-to-medium shape complexities if small part needs to be created [3]
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