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Spatial control of microstructure and material hardness in functionally graded stainless steels by DED-LB/M and in-situ alloying
Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Erlangen Graduate School in Advanced Optical Technologies (SAOT)The institution will open in a new tab, Konrad-Zuse-Straße 3, Erlangen, 91052, Germany; Bayerisches Laserzentrum GmbH, Konrad-Zuse-Straße 2-6, Erlangen, 91052, Germany.
Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Erlangen Graduate School in Advanced Optical Technologies (SAOT)The institution will open in a new tab, Konrad-Zuse-Straße 3, Erlangen, 91052, Germany; Bayerisches Laserzentrum GmbH, Konrad-Zuse-Straße 2-6, Erlangen, 91052, Germany.
Karlstad University, Faculty of Health, Science and Technology (starting 2013), Science, Mathematics and Engineering Education Research. Karlstad University, Faculty of Health, Science and Technology (starting 2013), Department of Engineering and Physics (from 2013).ORCID iD: 0000-0001-5140-9074
KSB SE & Co. KGaA, Bahnhofsplatz 1, Pegnitz, 91257, Germany.
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2025 (English)In: Journal of Materials Processing Technology, ISSN 0924-0136, E-ISSN 1873-4774, Vol. 340, article id 118867Article in journal (Refereed) Published
Abstract [en]

Duplex stainless steels (DSS) are characterized by a two-phased microstructure (δ-ferrite and γ-austenite) with equal phase fractions, providing an exceptional combination of high strength, toughness, and corrosion resistance. This duplex microstructure is conventionally achieved by a precise thermo-mechanical process (e.g., hot rolling) followed by multiple post-processing steps (coating, joining, assembly) to meet the requirements in high-performance applications (e.g., advanced wear and corrosion resistance). Laser directed energy deposition of metals (DED-LB/M) enables simultaneous processing of multiple materials in a single component, allowing for the customization of the functionality while reducing the number of process steps required. In this study, a 1.4462 DSS was manufactured by DED-LB/M and compositionally modified (in-situ alloyed) with increasing proportions of elemental Cr and/or Mo powder to control both the phase formation and material hardness. Subsequent solution annealing (1050 °C; 2 h) and quenching homogenized the as-built microstructure within each grading increment. Microstructure analysis (phase fraction, morphology, and grain size using electron backscattered diffraction) was correlated with the local chemical composition by energy dispersive X-ray spectroscopy. Hardness profiles along the grading direction indicated a gradual increase in material hardness due to the stabilization of δ-ferrite (+ 69 HV10) or σ-phase (+ 683 HV10) with the addition of Cr and/or Mo. This approach demonstrates that in-situ alloying in DED-LB/M facilitates the spatial control of phase structures and the customization of functional properties. Components can now be manufactured in a single process with smooth compositional transitions and locally enhanced material properties, e.g. ductile core with wear and corrosion resistant shell.

Place, publisher, year, edition, pages
Elsevier, 2025. Vol. 340, article id 118867
Keywords [en]
Additive manufacturing, Corrosion resistance, Directed energy deposition, Functionally graded materials, Microstructure, Stainless steel, Wear resistance, Brinell Hardness, Corrosion resistant alloys, Corrosion resistant coatings, Crystal lattices, Duplex stainless steel, Energy dispersive spectroscopy, In situ processing, Rockwell hardness, Steel corrosion, Customisation, Directed energy, Duplex stainless, Energy depositions, Functionally graded, Graded materials, Material hardness, Phase fractions, Spatial control
National Category
Materials Engineering
Research subject
Materials Engineering
Identifiers
URN: urn:nbn:se:kau:diva-104161DOI: 10.1016/j.jmatprotec.2025.118867Scopus ID: 2-s2.0-105002843577OAI: oai:DiVA.org:kau-104161DiVA, id: diva2:1955921
Available from: 2025-05-02 Created: 2025-05-02 Last updated: 2025-05-02Bibliographically approved

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Dimitrios, NikasKrakhmalev, Pavel

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2728293031323330 of 47
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