Efficient additive manufacturing of 2209 duplex stainless steel using multi-stranded wire plasma arc: Numerical simulation, microstructure and mechanical properties

IF 3.9 2区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Vacuum Pub Date : 2025-03-13 DOI:10.1016/j.vacuum.2025.114251

Haoquan Zhang , Kang Peng , Wenjun Wu , Liang Yu , Ramachandra Arvind Singh , Xizhang Chen

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Abstract

This study combines multi-stranded wires with plasma arc additive manufacturing (PAAM) to produce 2209 duplex stainless steel (2209 DSS). The PAAM process for multi-stranded 2209 DSS wire is explored through numerical simulation and experiments. Results show a 40 % increase in deposition rate compared to single wire. Numerical simulations suggest that depositing 10 layers under reciprocating deposition (RD) conditions at 1.4 kJ/cm thermal input stabilizes fabrication, minimizing residual stresses and harmful brittle phase formation. The resulting 2209 DSS thin-walled component exhibits excellent forming characteristics. Microstructure shows that overall two-phase ratio is close to ideal state (ferrite: austenite = 1:1), and there is no precipitation of detrimental brittle phase. Above experimental results demonstrate reliability of simulation model and validity of simulation results. In addition, component has excellent mechanical properties, and its overall average hardness is about 5 % higher than GB/T 4237-2015. Ultimate tensile strength (UTS) of whole component exceeds ASTM-A890 standard, with best tensile performance in middle region. Compared with GB/T 4237-2015, UTS, yield strength and elongation of middle region are 12 %, 45 % and 63 % higher, respectively.

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利用多股线等离子弧高效增材制造 2209 双相不锈钢：数值模拟、微观结构和机械性能

本研究将多股线与等离子弧增材制造（PAAM）相结合，生产2209双相不锈钢（2209 DSS）。通过数值模拟和实验对多股2209 DSS线材的PAAM工艺进行了探讨。结果表明，与单线相比，复合材料的沉积速率提高了40%。数值模拟表明，在1.4 kJ/cm的热输入条件下，在往复沉积（RD）条件下沉积10层可以稳定制造，最大限度地减少残余应力和有害脆性相的形成。得到的2209 DSS薄壁构件具有优异的成形特性。显微组织表明，整体两相比接近理想状态（铁素体：奥氏体= 1:1），无有害脆性相析出。以上实验结果验证了仿真模型的可靠性和仿真结果的有效性。此外，构件具有优异的力学性能，其整体平均硬度比GB/T 4237-2015高5%左右。整体构件极限抗拉强度（UTS）超过ASTM-A890标准，中间区域抗拉性能最佳。与GB/T 4237-2015相比，中部的屈服强度、屈服强度和延伸率分别提高了12%、45%和63%。

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来源期刊

Vacuum 工程技术-材料科学：综合

CiteScore

6.80

自引率

17.50%

发文量

审稿时长

34 days

期刊介绍： Vacuum is an international rapid publications journal with a focus on short communication. All papers are peer-reviewed, with the review process for short communication geared towards very fast turnaround times. The journal also published full research papers, thematic issues and selected papers from leading conferences. A report in Vacuum should represent a major advance in an area that involves a controlled environment at pressures of one atmosphere or below. The scope of the journal includes: 1. Vacuum; original developments in vacuum pumping and instrumentation, vacuum measurement, vacuum gas dynamics, gas-surface interactions, surface treatment for UHV applications and low outgassing, vacuum melting, sintering, and vacuum metrology. Technology and solutions for large-scale facilities (e.g., particle accelerators and fusion devices). New instrumentation ( e.g., detectors and electron microscopes). 2. Plasma science; advances in PVD, CVD, plasma-assisted CVD, ion sources, deposition processes and analysis. 3. Surface science; surface engineering, surface chemistry, surface analysis, crystal growth, ion-surface interactions and etching, nanometer-scale processing, surface modification. 4. Materials science; novel functional or structural materials. Metals, ceramics, and polymers. Experiments, simulations, and modelling for understanding structure-property relationships. Thin films and coatings. Nanostructures and ion implantation.