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Effect of hybrid manufacturing (am-machining) on the residual stress and pitting corrosion resistance of 316L stainless steel

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Abstract

The use of additive manufacturing (AM) has grown exponentially in recent years and has many advantages, including feasibility, over other conventional processes in many current applications. The use of a second process, for example, machining, improves the surface finish and in this case, the use of two processes is known as hybrid manufacturing. Heat treatments are often performed on parts generated by the AM process, mainly to relieve the residual stresses generated, but for some materials, this can decrease the pitting corrosion resistance of the parts. The objective of this study is to analyze the effect of hybrid manufacturing (AM + machining) on residual stresses and pitting resistance corrosion, which can bring advantages to piece properties without the use of heat treatment. 316L stainless steel parts are generated by direct laser metal sintering (DLMS), with subsequent milling using a complete factorial planning for the design of the experiments. The cutting speed, feed rate, cutting depth, use of the cutting fluid and laser power in the DLMS process are all varied. Residual stresses are measured by X-ray diffraction and the blind hole method, with polarization curves raised by a potentiostat. The results show that it is possible to reduce the residual surface stresses in the parts, even for compressive stresses, and to improve the pitting corrosion resistance, when compared to the part without milling, depending on the cutting parameters used.

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Acknowledgements

Authors would like to thank to the Maua Institute of Technology and São Paulo Research Foundation (Grant # 2020/10653-5, FAPESP; and Grant # 2020/09163-3, FAPESP) for the financial support. In addition, authors wish to acknowledge the 3DWIT for their assistance with Wire EDM of AM parts and the VAS Technology for the residual stress measurements.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University Center of Maua Institute of Technology, Praça Mauá, 01, Sao Caetano do Sul, 09580-900, Brazil

    Éd Claudio Bordinassi, Vanessa Seriacopi & Susana Marraccini Giampietri Lebrão

  2. Department of Mechanical Engineering, University Center of FEI, Av. Humberto de Alencar Castelo Branco, 3972, Sao Bernardo do Campo, 09580-901, Brazil

    Éd Claudio Bordinassi & Sergio Delijaicov

  3. South Eastern Applied Materials (SEAM) Research Centre, Waterford Institute of Technology, Applied Technology Building, Waterford, X91 TX03, Ireland

    Sinead Uí Mhurchadha & Ramesh Raghavendra

  4. School of Engineering, Waterford Institute of Technology, Waterford, X91 TX03, Ireland

    Ken Thomas & Ramesh Raghavendra

  5. Polytechnic School, University of Sao Paulo, Mechatronics and Mechanical Systems Engineering Department, Av. Prof. Mello Moraes, 2231, São Paulo, 05508-030, Brazil

    Gilmar Ferreira Batalha

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  1. Éd Claudio Bordinassi
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Correspondence to Éd Claudio Bordinassi.

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Bordinassi, É.C., Mhurchadha, S.U., Seriacopi, V. et al. Effect of hybrid manufacturing (am-machining) on the residual stress and pitting corrosion resistance of 316L stainless steel. J Braz. Soc. Mech. Sci. Eng. 44, 491 (2022). https://doi.org/10.1007/s40430-022-03813-3

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