Property-structure-process relationships in dissimilar material repair with directed energy deposition: Repairing gray cast iron using stainless steel 316L

Hamilton, Jakob D.; Sorondo, Samantha; Greeley, Andrew; Zhang, Xiao; Cormier, Denis; Li, Beiwen; Qin, Hantang; Rivero, Iris V.

doi:10.1016/j.jmapro.2022.06.015

Property-structure-process relationships in dissimilar material repair with directed energy deposition: Repairing gray cast iron using stainless steel 316L

Journal Article · Sat Jul 02 00:00:00 EDT 2022 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2022.06.015· OSTI ID:1977317

Hamilton, Jakob D. ^[1]; Sorondo, Samantha ^[2]; Greeley, Andrew ^[2]; Zhang, Xiao ^[3]; Cormier, Denis ^[2]; Li, Beiwen ^[3]; Qin, Hantang ^[3]; Rivero, Iris V. ^[2]

Rochester Institute of Technology, Rochester, NY (United States); OSTI
Rochester Institute of Technology, Rochester, NY (United States)
Iowa State University, Ames, IA (United States)

Directed energy deposition (DED) based remanufacturing leverages the flexibility of additive manufacturing to add value to broken or worn components. DED offers the ability to repair cast iron, a material difficult to repair with traditional welding techniques. Despite this, development of appropriate DED process conditions for bimetallic cast iron structures lags low- and medium-carbon steel repair. Thermal stresses and porosity generated by high-temperature deposition on cast iron often lower mechanical properties and hinder the qualification process. In this report scanning speed, powder mass flow rate, and stepover width are studied in multiple-track structures deposited on gray cast iron. Dilution and residual stresses are found to be highly dependent on the selected process parameters. Samples with a higher volumetric energy input, e.g., slower scanning speeds and higher powder feed rates, showed improved density and lower residual stresses but suffered lower dilution into the substrate. The presented conditions further the development of additive manufacturing technologies for automotive repair.

View Accepted Manuscript (DOE)

Research Organization:: Sustainable Manufacturing Innovation Alliance Corp., West Henrietta, NY (United States); Iowa State University, Ames, IA (United States); Rochester Institute of Technology, Rochester, NY (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0007897

OSTI ID:: 1977317

Alternate ID(s):: OSTI ID: 1876140

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Journal Issue: C Vol. 81; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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