Mechanical behavior of bimetallic stainless steel and gray cast iron repairs via directed energy deposition additive manufacturing

Hamilton, Jakob D.; Sorondo, Samantha; Li, Beiwen; Qin, Hantang; Rivero, Iris V.

doi:10.1016/j.jmapro.2022.12.029

Mechanical behavior of bimetallic stainless steel and gray cast iron repairs via directed energy deposition additive manufacturing

Journal Article · Wed Dec 28 04:00:00 EST 2022 · Journal of Manufacturing Processes

DOI:https://doi.org/10.1016/j.jmapro.2022.12.029· OSTI ID:2418581

Hamilton, Jakob D. ^[1]; Sorondo, Samantha ^[2]; Li, Beiwen ^[3]; Qin, Hantang ^[4]; Rivero, Iris V. ^[2]

Rochester Inst. of Technology, Rochester, NY (United States); OSTI
Rochester Inst. of Technology, Rochester, NY (United States)
Iowa State Univ., Ames, IA (United States)
Univ. of Wisconsin, Madison, WI (United States)

The utility of gray cast iron in engine components remains tied to the mechanical performance and cost. Repair and remanufacturing of castings offer economical and sustainable benefits; however, high thermal input from traditional fusion-based welding is unable to restore the original mechanical quality owing to brittle microstructures and porosity formed in situ. Directed energy deposition (DED) is an additive manufacturing method that has received considerable interest for repairs owing to the highly controllable nature of the process. Despite this, few works have connected the effect of DED parameters on actual interfacial strength. Consequently, distinct DED parameter combinations were identified to maximize the strength and fatigue life of the repaired cast iron. Further, high speed melt pool imaging and residual stress measurements are provided to aid in the understanding of the metallurgical quality and strength seen in these structures. In general, higher scanning speeds and lower thermal gradients promoted comparable tensile strength to that of the original gray cast iron. The results presented here provide a foundation to tune in the DED process to generate the required mechanical quality as a starting point for future process advancements.

View Accepted Manuscript (DOE)

Research Organization:: Sustainable Manufacturing Innovation Alliance Corp., West Henrietta, NY (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: EE0007897

OSTI ID:: 2418581

Alternate ID(s):: OSTI ID: 1907307

Journal Information:: Journal of Manufacturing Processes, Journal Name: Journal of Manufacturing Processes Journal Issue: C Vol. 85; ISSN 1526-6125

Publisher:: Society of Manufacturing Engineers; ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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