DED Powder Modification for Single-Layer Coatings on High-Strength Steels
In the design of L-DED (laser-directed energy deposition) cladding processes, the chemical composition of the metallic powders is typically assumed to match that of the intended coating. However, during the deposition of the first layer, dilution with the substrate alters the weld metal composition,...
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MDPI AG
2025-05-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/5/152 |
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| author | Unai Garate Enara Mardaras Jon Arruabarrena Garikoitz Artola Aitzol Lamikiz Luis Norberto López de Lacalle |
| author_facet | Unai Garate Enara Mardaras Jon Arruabarrena Garikoitz Artola Aitzol Lamikiz Luis Norberto López de Lacalle |
| author_sort | Unai Garate |
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| description | In the design of L-DED (laser-directed energy deposition) cladding processes, the chemical composition of the metallic powders is typically assumed to match that of the intended coating. However, during the deposition of the first layer, dilution with the substrate alters the weld metal composition, deviating from the nominal powder chemistry. Although the application of multiple layers can gradually reduce this dilution effect, it introduces additional complexity and processing time. This study proposes an alternative strategy to counteract substrate dilution from the very first deposited layer, eliminating the need for multilayer coatings. Specifically, to achieve a corrosion-resistant monolayer of AISI 316L stainless steel on a high-strength, quenched-and-tempered AISI 4140 steel substrate, a dilution-compensating alloy powder is added to the standard AISI 316L feedstock. Single-layer coatings, both with and without compensation, were evaluated in terms of chemical composition, microstructure, and corrosion resistance. The results show that unmodified coatings suffered a chromium depletion of approximately 2 wt.%, leading to a reduced pitting potential of Ep = 725 ± 6 mV in synthetic seawater. In contrast, the use of the compensation alloy preserved chromium content and significantly improved corrosion resistance, achieving a pitting potential of Ep = 890 ± 9 mV. |
| format | Article |
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| institution | OA Journals |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | MDPI AG |
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| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-5e0eb3a7cf784e3ca2e361816cb92d9b2025-08-20T01:56:31ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-05-019515210.3390/jmmp9050152DED Powder Modification for Single-Layer Coatings on High-Strength SteelsUnai Garate0Enara Mardaras1Jon Arruabarrena2Garikoitz Artola3Aitzol Lamikiz4Luis Norberto López de Lacalle5MESHIND, Aliendalde 5, 48200 Durango, SpainAZTERLAN, Basque Research and Technology Alliance (BRTA), 48200 Durango, SpainAZTERLAN, Basque Research and Technology Alliance (BRTA), 48200 Durango, SpainAZTERLAN, Basque Research and Technology Alliance (BRTA), 48200 Durango, SpainAeronautics Advanced Manufacturing Centre, Department of Mechanical Engineering, University of the Basque Country, 48013 Bilbao, SpainAeronautics Advanced Manufacturing Centre, Department of Mechanical Engineering, University of the Basque Country, 48013 Bilbao, SpainIn the design of L-DED (laser-directed energy deposition) cladding processes, the chemical composition of the metallic powders is typically assumed to match that of the intended coating. However, during the deposition of the first layer, dilution with the substrate alters the weld metal composition, deviating from the nominal powder chemistry. Although the application of multiple layers can gradually reduce this dilution effect, it introduces additional complexity and processing time. This study proposes an alternative strategy to counteract substrate dilution from the very first deposited layer, eliminating the need for multilayer coatings. Specifically, to achieve a corrosion-resistant monolayer of AISI 316L stainless steel on a high-strength, quenched-and-tempered AISI 4140 steel substrate, a dilution-compensating alloy powder is added to the standard AISI 316L feedstock. Single-layer coatings, both with and without compensation, were evaluated in terms of chemical composition, microstructure, and corrosion resistance. The results show that unmodified coatings suffered a chromium depletion of approximately 2 wt.%, leading to a reduced pitting potential of Ep = 725 ± 6 mV in synthetic seawater. In contrast, the use of the compensation alloy preserved chromium content and significantly improved corrosion resistance, achieving a pitting potential of Ep = 890 ± 9 mV.https://www.mdpi.com/2504-4494/9/5/152L-DEDdilutioncompensation alloycorrosionpitting potentialAISI 316L |
| spellingShingle | Unai Garate Enara Mardaras Jon Arruabarrena Garikoitz Artola Aitzol Lamikiz Luis Norberto López de Lacalle DED Powder Modification for Single-Layer Coatings on High-Strength Steels Journal of Manufacturing and Materials Processing L-DED dilution compensation alloy corrosion pitting potential AISI 316L |
| title | DED Powder Modification for Single-Layer Coatings on High-Strength Steels |
| title_full | DED Powder Modification for Single-Layer Coatings on High-Strength Steels |
| title_fullStr | DED Powder Modification for Single-Layer Coatings on High-Strength Steels |
| title_full_unstemmed | DED Powder Modification for Single-Layer Coatings on High-Strength Steels |
| title_short | DED Powder Modification for Single-Layer Coatings on High-Strength Steels |
| title_sort | ded powder modification for single layer coatings on high strength steels |
| topic | L-DED dilution compensation alloy corrosion pitting potential AISI 316L |
| url | https://www.mdpi.com/2504-4494/9/5/152 |
| work_keys_str_mv | AT unaigarate dedpowdermodificationforsinglelayercoatingsonhighstrengthsteels AT enaramardaras dedpowdermodificationforsinglelayercoatingsonhighstrengthsteels AT jonarruabarrena dedpowdermodificationforsinglelayercoatingsonhighstrengthsteels AT garikoitzartola dedpowdermodificationforsinglelayercoatingsonhighstrengthsteels AT aitzollamikiz dedpowdermodificationforsinglelayercoatingsonhighstrengthsteels AT luisnorbertolopezdelacalle dedpowdermodificationforsinglelayercoatingsonhighstrengthsteels |