A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SS
Nickel-based coatings have been demonstrated to effectively enhance the surface performance of stainless-steel components. The present study investigates the deposition efficiency and quality of Colmonoy 227-F nickel alloy coatings on AISI 304 stainless steel using direct energy deposition (DED). Th...
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MDPI AG
2025-07-01
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| author | Gabriele Grima Kamal Sleem Alberto Santoni Gianni Virgili Vincenzo Foti Marcello Cabibbo Eleonora Santecchia |
| author_facet | Gabriele Grima Kamal Sleem Alberto Santoni Gianni Virgili Vincenzo Foti Marcello Cabibbo Eleonora Santecchia |
| author_sort | Gabriele Grima |
| collection | DOAJ |
| description | Nickel-based coatings have been demonstrated to effectively enhance the surface performance of stainless-steel components. The present study investigates the deposition efficiency and quality of Colmonoy 227-F nickel alloy coatings on AISI 304 stainless steel using direct energy deposition (DED). The work focuses on the relationships between process parameters, microstructural features, and mechanical properties. A total of sixteen process parameter combinations were studied, varying laser power and scanning speed to establish optimal deposition conditions and to evaluate coating morphology, surface topology, dilution behavior, and mechanical performance. The surface geometry was analyzed using three-dimensional digital confocal microscopy. New material distribution (MD) indices were developed to quantify spatial uniformity and integrity of single coating scan tracks (CSTs) across the XY, XZ, and YZ planes. The optimal process was identified around 900 W laser power, balancing deposition efficiency and structural integrity. Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) reveal a gradual compositional transition between coating and substrate. The results of the microhardness test demonstrate a consistent gradient in mechanical properties, extending from the coating to the substrate. Coatings were found to achieve a hardness level of up to 600 HK. These findings establish a new benchmark for evaluating DED high-performance coatings and offer a scalable methodology for optimizing additive manufacturing processes in surface engineering applications. |
| format | Article |
| id | doaj-art-c982c5458b294e54bdbef408f440e7ef |
| institution | Kabale University |
| issn | 2073-4352 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | MDPI AG |
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| series | Crystals |
| spelling | doaj-art-c982c5458b294e54bdbef408f440e7ef2025-08-20T03:58:26ZengMDPI AGCrystals2073-43522025-07-0115762610.3390/cryst15070626A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SSGabriele Grima0Kamal Sleem1Alberto Santoni2Gianni Virgili3Vincenzo Foti4Marcello Cabibbo5Eleonora Santecchia6Department of Industrial Engineering and Mathematical Sciences, Università Politecnica Delle Marche, Via Brecce Bianche 12, 60131 Ancona, ItalyDepartment of Industrial Engineering and Mathematical Sciences, Università Politecnica Delle Marche, Via Brecce Bianche 12, 60131 Ancona, ItalyDepartment of Industrial Engineering and Mathematical Sciences, Università Politecnica Delle Marche, Via Brecce Bianche 12, 60131 Ancona, ItalyDepartment of Industrial Engineering and Mathematical Sciences, Università Politecnica Delle Marche, Via Brecce Bianche 12, 60131 Ancona, ItalyDepartment of Industrial Engineering and Mathematical Sciences, Università Politecnica Delle Marche, Via Brecce Bianche 12, 60131 Ancona, ItalyDepartment of Industrial Engineering and Mathematical Sciences, Università Politecnica Delle Marche, Via Brecce Bianche 12, 60131 Ancona, ItalyDepartment of Industrial Engineering and Mathematical Sciences, Università Politecnica Delle Marche, Via Brecce Bianche 12, 60131 Ancona, ItalyNickel-based coatings have been demonstrated to effectively enhance the surface performance of stainless-steel components. The present study investigates the deposition efficiency and quality of Colmonoy 227-F nickel alloy coatings on AISI 304 stainless steel using direct energy deposition (DED). The work focuses on the relationships between process parameters, microstructural features, and mechanical properties. A total of sixteen process parameter combinations were studied, varying laser power and scanning speed to establish optimal deposition conditions and to evaluate coating morphology, surface topology, dilution behavior, and mechanical performance. The surface geometry was analyzed using three-dimensional digital confocal microscopy. New material distribution (MD) indices were developed to quantify spatial uniformity and integrity of single coating scan tracks (CSTs) across the XY, XZ, and YZ planes. The optimal process was identified around 900 W laser power, balancing deposition efficiency and structural integrity. Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) reveal a gradual compositional transition between coating and substrate. The results of the microhardness test demonstrate a consistent gradient in mechanical properties, extending from the coating to the substrate. Coatings were found to achieve a hardness level of up to 600 HK. These findings establish a new benchmark for evaluating DED high-performance coatings and offer a scalable methodology for optimizing additive manufacturing processes in surface engineering applications.https://www.mdpi.com/2073-4352/15/7/626Colmonoy 227-FAISI 304 austenitic stainless steeldirected energy depositionhardfacingcoatingsmaterial deposition |
| spellingShingle | Gabriele Grima Kamal Sleem Alberto Santoni Gianni Virgili Vincenzo Foti Marcello Cabibbo Eleonora Santecchia A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SS Crystals Colmonoy 227-F AISI 304 austenitic stainless steel directed energy deposition hardfacing coatings material deposition |
| title | A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SS |
| title_full | A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SS |
| title_fullStr | A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SS |
| title_full_unstemmed | A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SS |
| title_short | A Novel Approach to Quantitatively Account on Deposition Efficiency by Direct Energy Deposition: Case of Hardfacing-Coated AISI 304 SS |
| title_sort | novel approach to quantitatively account on deposition efficiency by direct energy deposition case of hardfacing coated aisi 304 ss |
| topic | Colmonoy 227-F AISI 304 austenitic stainless steel directed energy deposition hardfacing coatings material deposition |
| url | https://www.mdpi.com/2073-4352/15/7/626 |
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