Abstract
Additive manufacturing of metallic components often results in the formation of columnar grain structures aligned along the build direction. These elongated grains can introduce anisotropy, negatively impacting the mechanical properties of the components. This study aimed to achieve controlled solidification with a fine-grained microstructure to enhance the mechanical performance of printed parts. Stainless steel 316L was used as the test material. High-intensity ultrasound was applied during the direct energy deposition (DED) process to inhibit the formation of columnar grains. The investigation emphasized the importance of amplitude changes of the ultrasound wave as the system’s geometry continuously evolves with the addition of multiple layers and assessed how these changes influence the grain size and distribution. Initial tests revealed significant amplitude fluctuations during layer deposition, highlighting the impact of layer deposition on process uniformity. The mechanical results demonstrated that the application of ultrasound effectively refined the grain structure, leading to a 15% increase in tensile strength compared to conventionally additively manufactured samples.
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