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Experimental characterization of stainless steel 316L alloy fabricated with combined powder bed fusion and directed energy deposition

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Abstract

Powder bed fusion (PBF) is an additive manufacturing (AM) technique commonly used to manufacture metallic components. External geometry of parts printed by PBF process can be extended by regular processes, namely, laser cladding and spraying powder metal. But these methods have disadvantages such as increased heat-affected zone (HAZ) and extended deficiencies like cracks and pores, whereas samples produced with directed energy deposition (DED) exhibited strong metallurgical bonding and has reduced HAZ due to least dilution. The present work investigates the properties of stainless steel 316L (SS316L) sandwich structure built by combining PBF and DED process. The external geometry of the SS316L samples built by PBF was extended by using DED technique. Metallurgical and mechanical characteristics of DED extended PBF samples were studied. Tensile properties such as percentage elongation and tensile strength were compared for PBF, DED, and SWS (DED extended PBF). It was found that the yield stress for the DED samples, PBF samples, and SWS samples is in the range of 486 MPa, 564 MPa, and 401 MPa. Moreover, the average hardness of the interface portion is found to be 220.5 HV and it is higher than the hardness observed in the PBF and DED regions.

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Abbreviations

AM:

Additive manufacturing

PBF:

Powder bed fusion

DED:

Directed energy deposition

SS316L:

Stainless steel 316L

HAZ:

Heat-affected zone

FESEM:

Field emission scanning electron microscope

EBSD:

Electron back scattered diagram

XRD:

X-ray powder diffraction

SWS:

Sandwich structures

EDAX:

Energy-dispersive X-ray spectrometer

DMLS:

Direct metal laser sintering

DMD:

Direct metal deposition

PR:

Powder feed rate (g/min)

SS:

Scanning speed (mm/min)

P:

Laser power (W)

E:

Energy density (J/mm2)

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Funding

This work was supported by the Central Manufacturing Technology Institute (CMTI), Department of Additive Manufacturing, Government of India. The authors thank Mr. A.R.Vinod, Scientist-C, and Mr. B.N. Manjunath, Scientist-B of AM lab, CMTI for their help during sample preparation.

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  1. Department of Production Engineering, National Institute of Technology Tiruchirappalli, Tiruchirappalli, Tamil Nadu, 620015, India

    M Kumaran & V Senthilkumar

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  1. M Kumaran
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Correspondence to V Senthilkumar.

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Recommended for publication by Commission I - Additive Manufacturing, Surfacing, and Thermal Cutting

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M, K., V, S. Experimental characterization of stainless steel 316L alloy fabricated with combined powder bed fusion and directed energy deposition. Weld World 65, 1373–1388 (2021). https://doi.org/10.1007/s40194-021-01117-z

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