Corrosion Resistance of 309L Stainless Steel Claddings on Carbon Steel Produced with Wire-Fed Directed Energy Deposition

Bozeman, Scott C.; Tucker, Julie D.; Isgor, O. Burkan

doi:10.5006/4268

Corrosion Resistance of 309L Stainless Steel Claddings on Carbon Steel Produced with Wire-Fed Directed Energy Deposition

Journal Article · Thu Apr 20 00:00:00 EDT 2023 · Corrosion

DOI:https://doi.org/10.5006/4268· OSTI ID:1989696

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Oregon State University, Corvallis, OR (United States); Oregon State University
Oregon State University, Corvallis, OR (United States)

Additive manufacturing (AM) tools are capable of applying overlay austenitic stainless steel (SS) claddings to carbon steel components. The benefits of this approach over arc welding include a smaller heat-affected zone, residual stress reduction, and material savings. In particular, wire-directed energy deposition is a suitable technique because of its low material cost and high rate of production compared to other AM methods. However, metallurgical variations in composition, phase fraction, and microsegregation can potentially influence the corrosion behavior of such claddings. In this work, 309L SS is clad on carbon steel substrates and electrochemical methods are used to measure their general and pitting corrosion resistance in simulated marine environments (3.5 wt% NaCl solutions). Two-layer claddings are fabricated with four laser powers to understand the effects of bulk chemical composition, austenite/δ-ferrite phase fractions, and individual phase compositions on corrosion behavior. The two-layer claddings are compared to a single-layer cladding, wrought 304 SS, and the carbon steel substrate for a comprehensive assessment of corrosion performance. The two-layer claddings are remarkably resistant to general corrosion in the 3.5 wt% NaCl environment because of their high Cr content (21.6 wt% to 23.3 wt% Cr). The single-layer cladding exhibits localized corrosion at unmixed Fe-rich peninsulas that originate at the dissimilar metal boundary and protrude into the first cladding layer. All two-layer claddings possess higher pitting corrosion resistance than wrought 304 SS, demonstrating their effectiveness as a corrosion-resistant barrier. Here, the pitting corrosion resistance is superior for claddings made with lower laser powers, due to low dilution and greater δ-ferrite contents.

View Accepted Manuscript (DOE)

Research Organization:: Oregon State University, Corvallis, OR (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Renewable Power Office. Water Power Technologies Office

Grant/Contract Number:: EE0009969

OSTI ID:: 1989696

Journal Information:: Corrosion, Journal Name: Corrosion Journal Issue: 7 Vol. 79; ISSN 0010-9312

Publisher:: NACE InternationalCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Carbon steel
Cladding
EIS
Pitting corrosion
Stainless steel
Welding

Corrosion Resistance of 309L Stainless Steel Claddings on Carbon Steel Produced with Wire-Fed Directed Energy Deposition

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