Interfacial characteristics of P91 steel - Inconel 740H bimetallic structure fabricated using wire-arc additive manufacturing
Abstract
Although bimetallic structures can offer unique solutions to engineering problems with varying functionality, joining two dissimilar alloys using additive manufacturing involves challenges such as cracking and segregation. In this work, bimetallic structures of Inconel 740H superalloy and P91 steel are processed using wire-arc additive manufacturing (WAAM) for the first time. P91 steel is directly deposited over 740H with a cooling time of 20 minutes in between the two depositions. During microstructure characterization, a large gradient zone with coarse grains spanning for ~2200 μm is observed. Moreover, the microhardness of the gradient zone is the least in comparison with the P91 and 740H deposits. No deleterious phase formation is found; however, intergranular cracks are observed along the gradient zone. In order to deduce the reason for cracking, non-equilibrium solidification simulations are performed for the mixed compositions of P91 and 740H in the gradient zone. Here, the reasons for crack formation in the gradient zone are the sudden change in the volumetric coefficient of thermal expansion due to the formation of MC carbides as well as the development of local strains from the thermal residual stresses. Therefore, altering the deposition sequence and introducing gradient layers with mixed composition between the P91 andmore »
- Authors:
-
[1]
- Univ. of Pittsburgh, PA (United States)
- Raytheon Technologies Research Center, East Hartford, CT (United States)
- Publication Date:
- Research Org.:
- Univ. of Pittsburgh, PA (United States)
- Sponsoring Org.:
- USDOE
- OSTI Identifier:
- 1842653
- Alternate Identifier(s):
- OSTI ID: 1826205
- Grant/Contract Number:
- FE0031637; DE‐FE0031637
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Journal of Materials Processing Technology
- Additional Journal Information:
- Journal Volume: 300; Journal ID: ISSN 0924-0136
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 20 FOSSIL-FUELED POWER PLANTS; 36 MATERIALS SCIENCE; 42 ENGINEERING; Processability; Dissimilar alloys; Coefficient of thermal expansion; Residual stress; Directed energy deposition
Citation Formats
Sridar, Soumya, Klecka, Michael A., and Xiong, Wei. Interfacial characteristics of P91 steel - Inconel 740H bimetallic structure fabricated using wire-arc additive manufacturing. United States: N. p., 2021.
Web. doi:10.1016/j.jmatprotec.2021.117396.
Sridar, Soumya, Klecka, Michael A., & Xiong, Wei. Interfacial characteristics of P91 steel - Inconel 740H bimetallic structure fabricated using wire-arc additive manufacturing. United States. https://doi.org/10.1016/j.jmatprotec.2021.117396
Sridar, Soumya, Klecka, Michael A., and Xiong, Wei. Wed .
"Interfacial characteristics of P91 steel - Inconel 740H bimetallic structure fabricated using wire-arc additive manufacturing". United States. https://doi.org/10.1016/j.jmatprotec.2021.117396. https://www.osti.gov/servlets/purl/1842653.
@article{osti_1842653,
title = {Interfacial characteristics of P91 steel - Inconel 740H bimetallic structure fabricated using wire-arc additive manufacturing},
author = {Sridar, Soumya and Klecka, Michael A. and Xiong, Wei},
abstractNote = {Although bimetallic structures can offer unique solutions to engineering problems with varying functionality, joining two dissimilar alloys using additive manufacturing involves challenges such as cracking and segregation. In this work, bimetallic structures of Inconel 740H superalloy and P91 steel are processed using wire-arc additive manufacturing (WAAM) for the first time. P91 steel is directly deposited over 740H with a cooling time of 20 minutes in between the two depositions. During microstructure characterization, a large gradient zone with coarse grains spanning for ~2200 μm is observed. Moreover, the microhardness of the gradient zone is the least in comparison with the P91 and 740H deposits. No deleterious phase formation is found; however, intergranular cracks are observed along the gradient zone. In order to deduce the reason for cracking, non-equilibrium solidification simulations are performed for the mixed compositions of P91 and 740H in the gradient zone. Here, the reasons for crack formation in the gradient zone are the sudden change in the volumetric coefficient of thermal expansion due to the formation of MC carbides as well as the development of local strains from the thermal residual stresses. Therefore, altering the deposition sequence and introducing gradient layers with mixed composition between the P91 and 740H deposits will be beneficial in achieving defect-free builds. Through the integration of experiments and simulation, this work gains valuable insights into the processability of dissimilar alloy manufacturing using the WAAM technique.},
doi = {10.1016/j.jmatprotec.2021.117396},
journal = {Journal of Materials Processing Technology},
number = ,
volume = 300,
place = {United States},
year = {Wed Oct 06 00:00:00 EDT 2021},
month = {Wed Oct 06 00:00:00 EDT 2021}
}
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