Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulation
Super duplex stainless steels (SDSSs) are often used in corrosive environments owing to their combination of good strength (>450 MPa yield strength and > 600 MPa ultimate tensile strength) and corrosion resistance (PREN > 40). In additive manufacturing (AM), the challenge is achieving phase...
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Elsevier
2025-06-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0264127525004472 |
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| author | Daysianne Kessy Mendes Isidorio João da Cruz Payão Filho Murali Uddagiri Kimiya NouraniNiaki Oleg Shchyglo Ingo Steinbach |
| author_facet | Daysianne Kessy Mendes Isidorio João da Cruz Payão Filho Murali Uddagiri Kimiya NouraniNiaki Oleg Shchyglo Ingo Steinbach |
| author_sort | Daysianne Kessy Mendes Isidorio |
| collection | DOAJ |
| description | Super duplex stainless steels (SDSSs) are often used in corrosive environments owing to their combination of good strength (>450 MPa yield strength and > 600 MPa ultimate tensile strength) and corrosion resistance (PREN > 40). In additive manufacturing (AM), the challenge is achieving phase balance and minimizing microsegregation to reduce sigma phase formation. This work employs multi-phase-field simulations to understand the solidification of a SDSS under AM, and experimental tests to analyze the microstructure and properties of a SDSS (AWS ER2594) deposited wall. Phase field solidification simulations showed epitaxial growth of δ dendrites, followed by solute segregation of ferritizing and austenitizing elements into the δ dendrite cores and interdendritic liquid, promoting γ phase nucleation. The deposited wall showed an almost 50/50 ferrite/austenite phase balance and minimum of 0.3 % of sigma phase, by ANOVA and Tukey analysis no significant difference between phase fraction at different regions, and a variation in microhardness values between the base (273 HV1) and upper (262 HV1) regions of the wall. These results indicate good homogenization and well-chosen AM process parameters for producing a SDSS wall. Nevertheless, this work improves the understanding of solidification, thus microstructural evolution, of SDSS under AM, and provides input for future models of solid-state transformations. |
| format | Article |
| id | doaj-art-3bd3127a904e4d1e948fe46f1a17af28 |
| institution | Kabale University |
| issn | 0264-1275 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj-art-3bd3127a904e4d1e948fe46f1a17af282025-08-20T03:46:41ZengElsevierMaterials & Design0264-12752025-06-0125411402710.1016/j.matdes.2025.114027Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulationDaysianne Kessy Mendes Isidorio0João da Cruz Payão Filho1Murali Uddagiri2Kimiya NouraniNiaki3Oleg Shchyglo4Ingo Steinbach5Programa de Engenharia Metalúrgica e de Materiais, Universidade Federal do Rio de Janeiro (UFRJ), Rio de Janeiro, Brazil; Interdisciplinary Centre for Advanced Materials Simulations (ICAMS), Ruhr Universität Bochum (RUB), Bochum, Germany; Corresponding authors at: Interdisciplinary Centre for Advanced Materials Simulations (ICAMS), Ruhr Universität Bochum (RUB), Bochum, Germany (D.K. Mendes Isidorio).Programa de Engenharia Metalúrgica e de Materiais, Universidade Federal do Rio de Janeiro (UFRJ), Rio de Janeiro, BrazilInterdisciplinary Centre for Advanced Materials Simulations (ICAMS), Ruhr Universität Bochum (RUB), Bochum, Germany; Corresponding authors at: Interdisciplinary Centre for Advanced Materials Simulations (ICAMS), Ruhr Universität Bochum (RUB), Bochum, Germany (D.K. Mendes Isidorio).Interdisciplinary Centre for Advanced Materials Simulations (ICAMS), Ruhr Universität Bochum (RUB), Bochum, GermanyInterdisciplinary Centre for Advanced Materials Simulations (ICAMS), Ruhr Universität Bochum (RUB), Bochum, GermanyInterdisciplinary Centre for Advanced Materials Simulations (ICAMS), Ruhr Universität Bochum (RUB), Bochum, GermanySuper duplex stainless steels (SDSSs) are often used in corrosive environments owing to their combination of good strength (>450 MPa yield strength and > 600 MPa ultimate tensile strength) and corrosion resistance (PREN > 40). In additive manufacturing (AM), the challenge is achieving phase balance and minimizing microsegregation to reduce sigma phase formation. This work employs multi-phase-field simulations to understand the solidification of a SDSS under AM, and experimental tests to analyze the microstructure and properties of a SDSS (AWS ER2594) deposited wall. Phase field solidification simulations showed epitaxial growth of δ dendrites, followed by solute segregation of ferritizing and austenitizing elements into the δ dendrite cores and interdendritic liquid, promoting γ phase nucleation. The deposited wall showed an almost 50/50 ferrite/austenite phase balance and minimum of 0.3 % of sigma phase, by ANOVA and Tukey analysis no significant difference between phase fraction at different regions, and a variation in microhardness values between the base (273 HV1) and upper (262 HV1) regions of the wall. These results indicate good homogenization and well-chosen AM process parameters for producing a SDSS wall. Nevertheless, this work improves the understanding of solidification, thus microstructural evolution, of SDSS under AM, and provides input for future models of solid-state transformations.http://www.sciencedirect.com/science/article/pii/S0264127525004472Phase-field methodWire arc additive manufacturingMulti-componentSolidificationMicrosegregation |
| spellingShingle | Daysianne Kessy Mendes Isidorio João da Cruz Payão Filho Murali Uddagiri Kimiya NouraniNiaki Oleg Shchyglo Ingo Steinbach Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulation Materials & Design Phase-field method Wire arc additive manufacturing Multi-component Solidification Microsegregation |
| title | Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulation |
| title_full | Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulation |
| title_fullStr | Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulation |
| title_full_unstemmed | Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulation |
| title_short | Super duplex stainless steel fabricated by arc-based directed energy deposition: Microstructure evolution and phase field solidification simulation |
| title_sort | super duplex stainless steel fabricated by arc based directed energy deposition microstructure evolution and phase field solidification simulation |
| topic | Phase-field method Wire arc additive manufacturing Multi-component Solidification Microsegregation |
| url | http://www.sciencedirect.com/science/article/pii/S0264127525004472 |
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