Additive manufacturing of functionally graded transition joints between ferritic and austenitic alloys

Zuback, J. S.; Palmer, T. A.; DebRoy, T.

doi:10.1016/j.jallcom.2018.08.197

Additive manufacturing of functionally graded transition joints between ferritic and austenitic alloys

Journal Article · Wed Aug 22 00:00:00 EDT 2018 · Journal of Alloys and Compounds

DOI:https://doi.org/10.1016/j.jallcom.2018.08.197· OSTI ID:1613870

Zuback, J. S. ^[1]; Palmer, T. A. ^[2]; DebRoy, T. ^[2]

Pennsylvania State University, University Park, PA (United States); DOE/OSTI
Pennsylvania State University, University Park, PA (United States)

Dissimilar metal joints between ferritic and austenitic alloys are susceptible to premature failure due to diffusive carbon loss from the ferritic alloy driven by abrupt changes in carbon chemical potential. Compositional grading of transition joints fabricated using laser-based directed energy deposition additive manufacturing offers a means for limiting carbon diffusion. In this report we fabricate functionally graded transition joints between a ferritic and austenitic alloy, characterize spatial variations of chemical composition, microstructure and hardness, and test their effectiveness to limit carbon loss from the ferritic alloy. Microstructural studies and carbon potential variations in the functionally graded material showed that the length of the joints can be shorter, and there is no benefit to continue compositional grading once the microstructure becomes fully austenitic. Since dissimilar joints have an expected lifetime of several decades, long service times were simulated through accelerated heat treatment experiments at elevated temperatures for both a dissimilar metal weld and a functionally graded transition joint. While the dissimilar weld showed pronounced carbon loss from the ferritic side, there was insignificant change in the carbon concentration profile in the functionally graded joint indicating effectiveness of the graded joints to perform under service conditions.

View Accepted Manuscript (DOE)

Research Organization:: Pennsylvania State University, University Park, PA (United States)

Sponsoring Organization:: USDOE; USDOE Office of Nuclear Energy (NE), Nuclear Energy University Program (NEUP)

Grant/Contract Number:: NE0008280

OSTI ID:: 1613870

Alternate ID(s):: OSTI ID: 1703724

Journal Information:: Journal of Alloys and Compounds, Journal Name: Journal of Alloys and Compounds Journal Issue: C Vol. 770; ISSN 0925-8388

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

References (30)

Application of Laser Engineered Net Shaping (LENS) to manufacture porous and functionally graded structures for load bearing implants Bandyopadhyay, Amit; Krishna, B. V.; Xue, Weichang Journal of Materials Science: Materials in Medicine, Vol. 20, Issue S1 https://doi.org/10.1007/s10856-008-3478-2	journal	June 2008
An assessment of creep deformation and fracture behavior of 2.25Cr-1Mo similar and dissimilar weld joints Laha, K.; Chandravathi, K. S.; Rao, K. Bhanu Sankara Metallurgical and Materials Transactions A, Vol. 32, Issue 1 https://doi.org/10.1007/s11661-001-0107-9	journal	January 2001
Fabrication of Fe-FeAl Functionally Graded Material Using the Wire-Arc Additive Manufacturing Process Shen, Chen; Pan, Zengxi; Cuiuri, Dominic Metallurgical and Materials Transactions B, Vol. 47, Issue 1 https://doi.org/10.1007/s11663-015-0509-5	journal	November 2015
Creep behaviour of post-weld heat-treated 2.25Cr-1Mo ferritic steel base, weld metal and weldments Laha, K.; Bhanu Sankara Rao, K.; Mannan, S. L. Materials Science and Engineering: A, Vol. 129, Issue 2 https://doi.org/10.1016/0921-5093(90)90265-5	journal	November 1990
Microstructural features of dissimilar welds between 316LN austenitic stainless steel and alloy 800 Sireesha, M.; Shankar, V.; Albert, Shaju K. Materials Science and Engineering: A, Vol. 292, Issue 1 https://doi.org/10.1016/S0921-5093(00)00969-2	journal	November 2000
Laser deposition of compositionally graded titanium–vanadium and titanium–molybdenum alloys Collins, P. C.; Banerjee, R.; Banerjee, S. Materials Science and Engineering: A, Vol. 352, Issue 1-2 https://doi.org/10.1016/S0921-5093(02)00909-7	journal	July 2003
Functionally graded material of 304L stainless steel and inconel 625 fabricated by directed energy deposition: Characterization and thermodynamic modeling Carroll, Beth E.; Otis, Richard A.; Borgonia, John Paul Acta Materialia, Vol. 108 https://doi.org/10.1016/j.actamat.2016.02.019	journal	April 2016
Additive manufacturing of a functionally graded material from Ti-6Al-4V to Invar: Experimental characterization and thermodynamic calculations Bobbio, Lourdes D.; Otis, Richard A.; Borgonia, John Paul Acta Materialia, Vol. 127 https://doi.org/10.1016/j.actamat.2016.12.070	journal	April 2017
Functionally graded Co–Cr–Mo coating on Ti–6Al–4V alloy structures Vamsi Krishna, B.; Xue, Weichang; Bose, Susmita Acta Biomaterialia, Vol. 4, Issue 3 https://doi.org/10.1016/j.actbio.2007.10.005	journal	May 2008
Residual stresses and distortion in additively manufactured compositionally graded and dissimilar joints Mukherjee, T.; Zuback, J. S.; Zhang, W. Computational Materials Science, Vol. 143 https://doi.org/10.1016/j.commatsci.2017.11.026	journal	February 2018
Bending and free vibration response of layered functionally graded beams: A theoretical model and its experimental validation Kapuria, S.; Bhattacharyya, M.; Kumar, A. N. Composite Structures, Vol. 82, Issue 3 https://doi.org/10.1016/j.compstruct.2007.01.019	journal	February 2008
Fracture mechanism of a dissimilar metal welded joint in nuclear power plant Wang, H. T.; Wang, G. Z.; Xuan, F. Z. Engineering Failure Analysis, Vol. 28 https://doi.org/10.1016/j.engfailanal.2012.10.005	journal	March 2013
Mechanical property variation within Inconel 82/182 dissimilar metal weld between low alloy steel and 316 stainless steel Jang, Changheui; Lee, Jounghoon; Sung Kim, Jong International Journal of Pressure Vessels and Piping, Vol. 85, Issue 9 https://doi.org/10.1016/j.ijpvp.2007.08.004	journal	September 2008
Evolution of microstructure and toughness in 2.25Cr-1Mo steel welds Elrefaey, Ahmed; Javadi, Yashar; Francis, John A. International Journal of Pressure Vessels and Piping, Vol. 165 https://doi.org/10.1016/j.ijpvp.2018.05.006	journal	August 2018
Modeling and control of a direct laser powder deposition process for Functionally Graded Materials (FGM) parts manufacturing Muller, Pierre; Mognol, Pascal; Hascoet, Jean-Yves Journal of Materials Processing Technology, Vol. 213, Issue 5 https://doi.org/10.1016/j.jmatprotec.2012.11.020	journal	May 2013
Effect of inter-layer dwell time on distortion and residual stress in additive manufacturing of titanium and nickel alloys Denlinger, Erik R.; Heigel, Jarred C.; Michaleris, Pan Journal of Materials Processing Technology, Vol. 215 https://doi.org/10.1016/j.jmatprotec.2014.07.030	journal	January 2015
Ferritic/martensitic steels for next-generation reactors Klueh, R. L.; Nelson, A. T. Journal of Nuclear Materials, Vol. 371, Issue 1-3 https://doi.org/10.1016/j.jnucmat.2007.05.005	journal	September 2007
Role of geometry on properties of additively manufactured Ti-6Al-4V structures fabricated using laser based directed energy deposition Keist, Jayme S.; Palmer, Todd A. Materials & Design, Vol. 106 https://doi.org/10.1016/j.matdes.2016.05.045	journal	September 2016
Chemical analysis, structure and mechanical properties of discrete and compositionally graded SS316–IN625 dual materials Savitha, U.; Jagan Reddy, G.; Venkataramana, A. Materials Science and Engineering: A, Vol. 647 https://doi.org/10.1016/j.msea.2015.09.001	journal	October 2015
Impact of iron composition on the properties of an additively manufactured solid solution strengthened nickel base alloy Khayat, Z. R.; Palmer, T. A. Materials Science and Engineering: A, Vol. 718 https://doi.org/10.1016/j.msea.2018.01.112	journal	March 2018
Additive manufacturing of metallic components – Process, structure and properties DebRoy, T.; Wei, H. L.; Zuback, J. S. Progress in Materials Science, Vol. 92 https://doi.org/10.1016/j.pmatsci.2017.10.001	journal	March 2018
Wear resistance of a functionally-graded aluminum matrix composite Melgarejo, Z. Humberto; Suárez, O. Marcelo; Sridharan, Kumar Scripta Materialia, Vol. 55, Issue 1 https://doi.org/10.1016/j.scriptamat.2006.03.031	journal	July 2006
Developing Gradient Metal Alloys through Radial Deposition Additive Manufacturing Hofmann, Douglas C.; Roberts, Scott; Otis, Richard Scientific Reports, Vol. 4, Issue 1 https://doi.org/10.1038/srep05357	journal	June 2014
Next-generation biomedical implants using additive manufacturing of complex, cellular and functional mesh arrays Murr, L. E.; Gaytan, S. M.; Medina, F. Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences, Vol. 368, Issue 1917 https://doi.org/10.1098/rsta.2010.0010	journal	April 2010
Development of nickel‐titanium graded composition components Domack, M. S.; Baughman, J. M. Rapid Prototyping Journal, Vol. 11, Issue 1 https://doi.org/10.1108/13552540510573383	journal	February 2005
Performance of Dissimilar Welds in Service Roberts, D. I.; Ryder, R. H.; Viswanathan, R. Journal of Pressure Vessel Technology, Vol. 107, Issue 3 https://doi.org/10.1115/1.3264443	journal	August 1985
Microstructural evolution and high temperature failure of ferritic to austenitic dissimilar welds DuPont, J. N. International Materials Reviews, Vol. 57, Issue 4 https://doi.org/10.1179/1743280412Y.0000000006	journal	July 2012
Site specific control of crystallographic grain orientation through electron beam additive manufacturing Dehoff, R. R.; Kirka, M. M.; Sames, W. J. Materials Science and Technology, Vol. 31, Issue 8 https://doi.org/10.1179/1743284714Y.0000000734	journal	November 2014
Precipitation sequences during carburisation of Cr–Mo steel Race, J. M.; Bhadeshia, H. K. D. H. Materials Science and Technology, Vol. 8, Issue 10 https://doi.org/10.1179/mst.1992.8.10.875	journal	October 1992
Computational thermodynamics and the kinetics of martensitic transformation Ghosh, G.; Olson, G. B. Journal of Phase Equilibria, Vol. 22, Issue 3 https://doi.org/10.1361/105497101770338653	journal	May 2001

Cited By (1)

The Hardness of Additively Manufactured Alloys Zuback, J. S.; DebRoy, T. Materials, Vol. 11, Issue 11 https://doi.org/10.3390/ma11112070	journal	October 2018

Similar Records

Microstructure characteristics of LPBF&HIP fabricated graded composite transition joint between ferritic steel and austenitic stainless steel

Journal Article · Fri Sep 05 20:00:00 EDT 2025 · Additive Manufacturing · OSTI ID:3002130

Heterogeneous creep deformation behavior of functionally graded transition joints (GTJs)

Journal Article · Tue Apr 27 20:00:00 EDT 2021 · Welding in the World · OSTI ID:1819529

Design, Fabrication, and Characterization of Graded Transition Joints

Journal Article · Mon Jul 31 20:00:00 EDT 2017 · Welding Journal · OSTI ID:1410953

Related Subjects

36 MATERIALS SCIENCE
diffusion
dissimilar metal joints
ferritic and austenitic alloys
functionally graded materials
laser additive manufacturing

Additive manufacturing of functionally graded transition joints between ferritic and austenitic alloys

Citation Formats

References (30)

Cited By (1)

Similar Records

Related Subjects