Professional Documents
Culture Documents
The double-wire feed and plasma arc additive manufacturing process for T
deposition in Cr-Ni stainless steel
⁎
Yuehai Feng , Bin Zhan, Jie He, Kehong Wang
School of Materials Science and Engineering, Nanjing University of Science and Technology, Nanjing 210094, PR China
A R T I C LE I N FO A B S T R A C T
Keywords: This paper proposes an innovative and high efficiency process to fabricate Cr-Ni stainless steel components using
Double-Wire feed a double-wire feed and plasma arc additive manufacturing process (DWF-PAM). The superior characteristics
Plasma arc additive manufacturing exhibited by DWF-PAM processing in terms of the bead appearance, microstructure, and mechanical properties
Microstructure of all the test components, were investigated. The results show that, at the same process parameters, in contrast
Mechanical properties
to the single-wire feed and plasma additive manufacturing (SWF-PAM) process, the deposition rate in the DWF-
PAM process increased by 1.06 times on an average. A large number of complete grown equiaxed ferrite (CGEF)
grains were found in the interface area close to the next layer of the DWF-PAM-processed sample; while for the
SWF-PAM-processed samples, incomplete grown equiaxed ferrite grains were observed in same area. The CGEF
grains provided a significant improvement to the ultimate tensile strengths and elongation rates of the DWF-
PAM-processed samples. The ultimate tensile strength increased by 10.2% on an average, while the maximal
increment of the elongation rate reached 176%. In view of these results, components manufactured by the DWF
process can have a finer-grained microstructure and superior mechanical properties compared to those manu-
factured by the SWF process. Moreover, a higher deposition rate can also be achieved with the DWF-PAM
process.
1. Introduction powder-based manufacturing process, the wire and arc additive man-
ufacturing (WAAM) process has the advantages of low manufacturing
Additive manufacturing processes employ an advanced ‘bottom-up’ costs, high forming efficiencies, and the ability to manufacture all-dense
material manufacturing method, which adopts layer-by-layer accumu- components, as described in Syed et al. (2005). However, it has been
lation in a near-net-shape process, as described by Wang et al. (2013). challenging to substantially increase the deposition rate in WAAM.
Compared with traditional subtractive manufacturing processes which Stainless steel has excellent mechanical properties and corrosion
have multi-channel processing procedures, additive manufacturing resistance, and is used in all aspects of life for a wide range of appli-
processes save materials and energy, and shorten the processing cycle cations, especially for pressure vessels in nuclear experimental reactors.
of parts, according to Ding et al. (2015). Through three-dimensional Research on stainless-steel additive manufacturing processes is more
program design, it can precisely manufacture complex parts and surpass thorough. Luecke and Slotwinski (2014) used uniaxial tensile tests and
the limits of traditional processes. Dutta et al. (2011) described a direct micro hardness tests to demonstrate the anisotropy of the mechanical
metal deposition technology used to manufacture new components. properties for additive-manufactured austenitic stainless steels, which
Metal-based material manufacturing processes can be divided into was superior than that obtained by the conventional forging technique.
powder-based additive manufacturing and wire-based additive manu- Zhong et al. (2017) described how the mechanical properties and mi-
facturing. According to Sing et al. (2016), the powder-based additive crostructure of 316 L components for nuclear pressure vessels are af-
manufacturing process mainly adopts an electron beam and laser as the fected by the electron beam melting process. Skiba et al. (2009) in-
heat source, forming parts with high precision that require less follow- vestigated the microstructure and mechanical properties of a 308
up processing; however, this process has limitations due to high costs stainless-steel wire using a gas tungsten arc welding (GTAW)-based
and a low efficiency. Jerby et al. (2015) also described microwave shape metal deposition process. Although there have been many studies
energy is also proven a low cost heat source for metal powder additive on additive-manufactured stainless steels, it is still challenging to im-
manufacturing, however, its efficiency is still lower. Compared with the prove the deposition rate of this process.
⁎
Corresponding author.
E-mail address: fyh@njust.edu.cn (Y. Feng).
https://doi.org/10.1016/j.jmatprotec.2018.04.040
Received 10 August 2017; Received in revised form 23 April 2018; Accepted 24 April 2018
Available online 25 April 2018
0924-0136/ © 2018 Elsevier B.V. All rights reserved.
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
Table 1 Table 2
Chemical compositions of the wire and substrate (wt. %). Process parameters of deposited walls in multi-layer single-bead.
Cr Ni C Si Mn S P N Fe Process Number Deposited Deposited Deposited Wire feed
current/A Voltage/V speed/cm/ speed/m/
Wire 20.0 10.0 0.03 0.60 1.80 0.008 0.015 – Bal. min mindinesh
Substrate 19.0 9.0 ≤0.08 ≤1.0 ≤2.0 ≤0.03 ≤0.035 ≤0.1 Bal.
SWF-PAM 1 130 27.3 30 1.5
2 130 27.2 50 1.5
3 130 27.6 60 1.5
In comparison with GTAW-based additive manufacturing and Gas DWF-PAM 4 130 27.8 30 1.5 1.5
5 130 27.5 50 1.5 1.5
Metal arc welding (GMAW)-base additive manufacturing, the plasma 6 130 27.4 60 1.5 1.5
arc welding (PAW)-base additive manufacturing process has the ad-
vantages of a concentrated arc, higher energy density, and higher
forming precision. The plasma arc additive manufacturing process is
considered as a better method for manufacturing high-quality
207
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
Fig. 4. Photographs of deposited walls: a), b), and c) present the DWF-PAM
2. Experimental
samples processed at speeds of 30 cm/min, 50 cm/min, and 60 cm/min, re-
spectively; d), e), and f) present the SWF-PAM samples processed at speeds of
30 cm/min, 50 cm/min, and 60 cm/min, respectively. A robotic plasma arc additive manufacturing system, as described in
Fig. 1(a), was used to fabricate the components. It consists of a 400 A
GTAW power source (Fronius MagicWave3000), a water-cooled plasma
welding torch mounted on a 6-axis industrial robot (Yaskawa MO-
TOMAN MH6), a self-developed plasma arc generation device, and two
automatic constant-wire feeder equipment to ensure consistent plasma
transferred arc deposition. The experiment setup is shown in Fig. 1(b).
A H00Cr21Ni10 stainless steel wire with a diameter of 1.0 mm was
used as the experimental material; the nominal compositions of the
wire and the substrate are listed in Table 1. A wrought 08Cr19Ni9
stainless steel base plate was used as the substrate for the deposits. Pure
argon (99.99%) was used as a shielding gas and plasma generation gas
at a constant flow rate of 18 L/min and 0.8 L/min, respectively. The
surface of the substrate was polished by a grinding machine to remove
the oxide layer, and the organic matter was cleaned by acetone. De-
position layers were then built by moving the plasma welding torch and
feeding wire into the molten pool. A ‘back-and-forth’ deposition
method, that the next deposition layer starting location is same place as
the end of the front layer, was used in this experiment. During the
deposition process, a stand-off distance of 8 mm was found to be sui-
Fig. 5. Sketch of deposited wall section.
table for double-wire feeding to the melt pool. The additive-manu-
factured multi-layer wall samples were approximately 200 mm long.
components, especially for large-scale complex shape parts, and much Each experimental sample comprised of 70 deposited layers.
research has been carried out on this process. Sánchez-Tovar et al. To study the effects of the deposited speed on the bead appearance,
(2011) explained the dependence of the properties and microstructure microstructures, and mechanical properties of the stainless steels, three
of AISI 316 L stainless steels in heavy LiBr brines on the micro-plasma groups of deposition experiments each for the DWF-PAM and SWF-PAM
arc welding process. Jhavar et al. (2014) described the fabrication of processes, were implemented. These process parameters are listed in
208
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
Fig. 6. SWF-PAM and DWF-PAM deposited walls macroscopic:(a) average height;(b) average width.
Fig. 7. The cross-section microstructure (a) and three regions of the deposited layer microstructures (b).
209
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
210
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
Fig. 10. Influence of the deposited speed for the SWF-PAM and DWF-PAM processes on: (a) ultimate tensile strength; (b) elongation rate.
phase transformation occurs, resulting in differences in the micro- speed. The microstructures were finer in the DWF-PAM-processed
structure. The microstructures of the deposited samples present three samples than in the SWF-PAM-processed ones.
typical sections: a top section, middle section, and bottom section, as
observed in Fig. 7 (a). Of all three sections, the deposited quality and 3.3. Tensile test
mechanical properties of the middle section are most crucial for fabri-
cating components. The microstructure in a DWF-PAM-processed Fig. 10(a) exhibits the relationship between the ultimate tensile
sample are presented in Fig. 7(b). It is characterised by the existence of strength and deposited speed for the SWF-PAM process and DWF-PAM
the ferrite (δ−Fe) phase on the finer austenite matrix. From the bottom process. The ultimate tensile strengths of the deposition wall, were
to the top in each layer, the fine grain region growing along the in- measured along both the vertical and horizontal directions: 30v, 50v,
terface of the front layer, the columnar grain region growing gradually, and 60v for 30 cm/min, 50 cm/min and 60 cm/min in the vertical di-
and the equiaxed grain region adjacent to the next layer, are distributed rection, respectively, and 30h, 50h, and 60h for 30 cm/min, 50 cm/min,
in turn. These structures are also visible in the SWF-PAM-processed and 60 cm/min in the horizontal direction, respectively. The following
sample. figures use the same expressions. The DWF-PAM specimens appear to
The micrographs in Fig. 8 show the influence of the deposited speed have a higher ultimate strength than the SWF-PAM specimens, as
and the two processes on the microstructure in the adjacent area be- shown in Fig. 10(a). Their ultimate strength increased by 10.2% on an
tween the 35th layer and 36th layer of these fabricated walls. As seen in average, approximately by 52.98 MPa. The evident improvement in the
Fig. 8(b), (d), and (f), a large number of complete grown equiaxed ultimate tensile strength can be explained by the fact that the CGEF
ferrite (CGEF) grains can be observed in the interface adjacent to the grains prevail in the interface area adjacent to next layer. It also can be
next layer of the DWF-PAM-processed samples. Moreover, with an in- concluded that, the ultimate tensile strength increased for both the
crease in the deposited speed from 30 cm/min to 60 cm/min, the DWF-PAM and SWF-PAM processes, for deposition speeds ranging from
quantity of the CGEF grains visibly increases. In contrast, for the SWF- 30 cm/min to 60 cm/min. Fig. 10(a) shows that the ultimate tensile
PAM-processed samples, a number of incomplete grown equiaxed fer- strengths for the same samples in the vertical and horizontal directions
rite (IGEF) grains can be observed in Fig. 8(a), (c), and (e), while only a are similar.
few CGEF grains can be found in Fig. 8(e). In addition, with an increase The DWF-PAM process provided elongation rates of 44.7%–58.7%,
in the deposited speed from 30 cm/min to 50 cm/min, the amount of while the SWF-PWM process provided elongation rates between 20.5%
IGEF grains clearly increases. However, when the deposited speed is up and 35.4%, as shown in Fig. 10(b). The maximum increase in the
to 60 cm/min, the amount of IGEF grains decreases, and only a few elongation rate of the DWF-PWM sample was found to reach 176%, and
CGEF grains can be observed. Ye et al. (2013) showed that CGEF grains even the maximum increase in elongation rate also reaches 39%. Thus,
considerably enhance the mechanical properties. This effect can be there is a significant increment in elongation for all the DWF-PWM
attributed to the two wires melting in the same melt pool, augmenting samples. The manifold increase in the elongation rates can also be ex-
the cooling rate to form a finer CGEF structure. Another reason is that plained by the fact that CGEF grains are distributed in the interface area
the increased deposited speed also brings about a more rapid adjacent to the next layer of the DWF-PWM sample; the finer the CGEF
quenching, leading to better grain structures. grains, the higher the elongation rates of the deposited wall.
The sizes of the twenty, randomly selected ferrite grains were The microscopic fracture morphologies of these deposited samples
measured, and a statistical curve of their average grain diameters is analysed by SEM are displayed in Fig. 11. Numerous dimples can be
displayed Fig. 9. It should be noted that, for the same deposited speed, seen in all the samples, and the morphology is dominated by ductile
the grain diameters of the DWF-PAM-processed samples are sig- fracture. The dimples in the SWF-PAM-processed samples along the
nificantly smaller than those of the SWF-PAM-processed samples. vertical direction become smaller with the increase in the deposited
Moreover, for the DWF-PAM-processed samples, at deposition speeds of speed, as illustrated in Fig. 11(a), (e) and (j); those along the horizontal
30 cm/min, 50 cm/min, and 70 cm/min, the average grain diameter is direction also show a similar trend. As compared to the SWF-PAM-
11.67 μm, 9.52 μm, and 8.96 μm, respectively; this is significantly processed samples, for the same deposited speed and along the same
smaller than the average grain diameters (20.93 μm, 15.18 μm and direction, the dimples are visibly smaller and greater in number in the
11.14 μm) of the SWF-PAM-processed samples of the same deposited DWF-PAM-processed samples. The number of second-phase spherical
211
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
particles and the amount of dimples formed are also more in these found in the first three layers, as seen in Fig. 13(a), (b), and (c). After
samples than in SWF-PAM-processed samples, as indicated in Fig. 12. the 10th layer, the fluctuation range of micro-hardness for all samples
These results indicate that the toughness of a DWF-PAM-processed tends to stable, and ranges from 170 HV to 210 HV, as seen in Fig. 13.
sample is better than that of a SWF-PAM-processed sample, for the Similar hardness distributions were measured for the other deposited
corresponding elongation rates. speeds. The mean hardness values for each of the SWF-PAM-processed
samples at three deposition speeds were as follows: 194.01 HV at
3.4. Hardness distribution 30 cm/min, 190.37 HV at 50 cm/min, and 194.20 HV at 70 cm/min.
The mean hardness values of the SWF-PAM-processed samples at the
Fig. 13 displays the micro-Vickers hardness distributions of the same speeds were 185.17 HV, 186.35 HV, and 188.66 HV, respectively.
SWF-PAM- and DWF-PAM-processed samples for different deposition The mean hardness values thus show no significant difference for both
speeds. Fig. 13(a) shows a maximum measured hardness of 233.3 HV in processes. The reason for this is that the interlayer stand-by times for
the first layer for the SWF-PAM process, 221.5 HV in the second layer both processes were set to two minutes; hence, the interlayer tem-
for the DWF-PAM process. The maximal hardness values are generally peratures also tend to be similar.
Fig. 11. Fracture morphologies of deposited walls: the left is the SWF-PAM process; the right is the DWF-PAM process.
212
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
213
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
Fig. 12. Second phase spherical particles of: (a) SWF-PAM process sample and (b) DWF-PAM process sample.
214
Y. Feng et al. Journal of Materials Processing Tech. 259 (2018) 206–215
215