Microstructure and Mechanical Properties of AISI 316L Produced by Directed Energy Deposition-Based Additive Manufacturing: A Review

Directed energy deposition (DED) as a metal additive manufacturing technology can be used to produce or repair complex shape parts in a layer-wise process using powder or wire. Thanks to its advantages in the fabrication of net-shape and functionally graded components, DED could attract significant interest in the production of high-value parts for different engineering applications. Nevertheless, the industrialization of this technology remains challenging, mainly because of the lack of knowledge regarding the microstructure and mechanical characteristics of as-built parts, as well as the trustworthiness/durability of engineering parts produced by the DED process. Hence, this paper reviews the published data about the microstructure and mechanical performance of DED AISI 316L stainless steel. The data show that building conditions play key roles in the determination of the microstructure and mechanical characteristics of the final components produced via DED. Moreover, this review article sheds light on the major advancements and challenges in the production of AISI 316L parts by the DED process. In addition, it is found that in spite of different investigations carried out on the optimization of process parameters, further research efforts into the production of AISI 316L components via DED technology is required.

[1]  M. Flemings Solidification processing , 1974, Metallurgical and Materials Transactions B.

[2]  H. Engström Laser cladding by powder injection , 1990 .

[3]  T. DebRoy,et al.  Development of macro- and microstructures of carbon–manganese low alloy steel welds: inclusion formation , 1995 .

[4]  J. Mazumder,et al.  The direct metal deposition of H13 tool steel for 3-D components , 1997 .

[5]  R. Colaço,et al.  Phase selection during laser surface melting of martensitic stainless tool steels , 1997 .

[6]  D. Keicher,et al.  LENSTM moves beyond RP to direct fabrication , 1998 .

[7]  G. K. Lewis,et al.  Directed light fabrication of a solid metal hemisphere using 5-axis powder deposition , 1998 .

[8]  Ali Alagheband,et al.  Plasma Atomization goes commercial , 1998 .

[9]  M. L. Griffith,et al.  Investigation of Solidification in the Laser Engineered Net shaping (LENS) Process , 1999 .

[10]  M. L. Griffith,et al.  Understanding thermal behavior in the LENS process , 1999 .

[11]  M. L. Griffith,et al.  Understanding the Microstructure and Properties of Components Fabricated by Laser Engineered Net Shaping (LENS) , 2000 .

[12]  Noboru Kikuchi,et al.  Closed loop direct metal deposition : art to part , 2000 .

[13]  M. Grujicic,et al.  Computer simulations of the evolution of solidification microstructure in the LENS™ rapid fabrication process , 2001 .

[14]  M. L. Griffith,et al.  Solidification in direct metal deposition by LENS processing , 2001 .

[15]  W. Kurz Solidification microstructure-processing maps: Theory and application , 2001 .

[16]  P. Kobryn,et al.  Mechanical Properties of Laser-Deposited Ti-6Al-4V , 2001 .

[17]  Rui M. Vilar,et al.  Laser cladding , 2003, Advanced Laser Technologies.

[18]  Lin Li,et al.  Mechanical and electrochemical properties of multiple-layer diode laser cladding of 316L stainless steel , 2005 .

[19]  Jun Zhang,et al.  Adaptive slicing for a multi-axis Laser Aided Manufacturing Process , 2004 .

[20]  Lin Li,et al.  A comparative study of wire feeding and powder feeding in direct diode laser deposition for rapid prototyping , 2005 .

[21]  Jing Liang,et al.  Microstructures of laser-deposited Ti–6Al–4V , 2004 .

[22]  S. Kelly,et al.  Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part II. Thermal modeling , 2004 .

[23]  S. Kelly,et al.  Microstructural evolution in laser-deposited multilayer Ti-6Al-4V builds: Part I. Microstructural characterization , 2004 .

[24]  A. Durgutlu,et al.  Experimental study of the effect of hydrogen in argon as a shielding gas in MIG welding of austenitic stainless steel , 2005 .

[25]  J. Choi,et al.  Modeling and Experimental Verification of Transient/Residual Stresses and Microstructure Formation in Multi-Layer Laser Aided DMD Process , 2006 .

[26]  R. Poprawe,et al.  Characterization of the process control for the direct laser metallic powder deposition , 2006 .

[27]  Q. Deng,et al.  Rebuilding of metal components with laser cladding forming , 2006 .

[28]  H. Fraser,et al.  Thermal process maps for predicting solidification microstructure in laser fabrication of thin-wall structures , 2006 .

[29]  E. Lavernia,et al.  Numerical modeling of the thermal behavior during the LENS® process , 2006 .

[30]  Frank W. Liou,et al.  Applications of a hybrid manufacturing process for fabrication of metallic structures , 2007 .

[31]  J. Berry,et al.  Phase transformations in low-alloy steel laser deposits , 2008 .

[32]  R. Kaçar,et al.  An effect of heat input, weld atmosphere and weld cooling conditions on the resistance spot weldability of 316L austenitic stainless steel , 2008 .

[33]  J. Schoenung,et al.  Thermal Behavior and Microstructural Evolution during Laser Deposition with Laser-Engineered Net Shaping: Part I. Numerical Calculations , 2008 .

[34]  M. L. Griffith,et al.  Laser Engineered Net Shaping ( LENSTM ) Process : Optimization of Surface Finish and Microstructural Properties , 2008 .

[35]  H. Fraser,et al.  Effects of process variables and size-scale on solidification microstructure in beam-based fabrication of bulky 3D structures , 2009 .

[36]  S. Felicelli,et al.  Dendrite growth simulation during solidification in the LENS process , 2010 .

[37]  C. Selcuk Laser metal deposition for powder metallurgy parts , 2011 .

[38]  L. M. Kukreja,et al.  Studies on pitting corrosion and sensitization in laser rapid manufactured specimens of type 316L stainless steel , 2012 .

[39]  William E. Frazier,et al.  Metal Additive Manufacturing: A Review , 2014, Journal of Materials Engineering and Performance.

[40]  M. Lima,et al.  Microstructure and mechanical behavior of laser additive manufactured AISI 316 stainless steel stringers , 2014 .

[41]  L. M. Kukreja,et al.  Fatigue Crack Propagation and Fracture Toughness of Laser Rapid Manufactured Structures of AISI 316L Stainless Steel , 2014, Metallography, Microstructure, and Analysis.

[42]  S. Wang,et al.  Characterization of stainless steel parts by Laser Metal Deposition Shaping , 2014 .

[43]  Zhijian Shen,et al.  Transformation of austenite to duplex austenite-ferrite assembly in annealed stainless steel 316L consolidated by laser melting , 2015 .

[44]  N. Shamsaei,et al.  Microstructural Features and Mechanical Properties of 316L Stainless Steel fabricated by Laser Additive Manufacture , 2015 .

[45]  N. Shamsaei,et al.  An overview of Direct Laser Deposition for additive manufacturing; Part II: Mechanical behavior, process parameter optimization and control , 2015 .

[46]  I. Gibson,et al.  Directed Energy Deposition Processes , 2015 .

[47]  Y. Zhong,et al.  Hardened austenite steel with columnar sub-grain structure formed by laser melting , 2015 .

[48]  N. Shamsaei,et al.  Effects of process time interval and heat treatment on the mechanical and microstructural properties of direct laser deposited 316L stainless steel , 2015 .

[49]  J. Schoenung,et al.  Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering , 2017, Journal of Thermal Spray Technology.

[50]  Min-Gyu Lee,et al.  Effect of Energy Input on the Characteristic of AISI H13 and D2 Tool Steels Deposited by a Directed Energy Deposition Process , 2016, Metallurgical and Materials Transactions A.

[51]  M. Ziętala,et al.  The microstructure, mechanical properties and corrosion resistance of 316 L stainless steel fabricated using laser engineered net shaping , 2016 .

[52]  A. Beese,et al.  Effect of processing parameters on microstructure and tensile properties of austenitic stainless steel 304L made by directed energy deposition additive manufacturing , 2016 .

[53]  B. Graf,et al.  Laser Metal Deposition as Repair Technology for a Gas Turbine Burner Made of Inconel 718 , 2016 .

[54]  Zemin Wang,et al.  A comparison on metallurgical behaviors of 316L stainless steel by selective laser melting and laser cladding deposition , 2017 .

[55]  Joshua D. Gale,et al.  Application of ultrasonic peening during DMLS production of 316L stainless steel and its effect on material behavior , 2017 .

[56]  A. Valente,et al.  Monitoring Approach to Evaluate the Performances of a New Deposition Nozzle Solution for DED Systems , 2017 .

[57]  J. Schoenung,et al.  In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing , 2017 .

[58]  Peng Guo,et al.  Study on microstructure, mechanical properties and machinability of efficiently additive manufactured AISI 316L stainless steel by high-power direct laser deposition , 2017 .

[59]  M. Pavese,et al.  Effect of Sample Preparation on the Microstructural Evaluation of Al–GNPs Nanocomposites , 2017, Metallography, Microstructure, and Analysis.

[60]  S. Biamino,et al.  An Overview of Additive Manufacturing of Titanium Components by Directed Energy Deposition: Microstructure and Mechanical Properties , 2017 .

[61]  M. Pavese,et al.  An Overview of Metal Matrix Nanocomposites Reinforced with Graphene Nanoplatelets; Mechanical, Electrical and Thermophysical Properties , 2018, Metals.

[62]  Jacob O Sutton,et al.  Impact of Defects in Powder Feedstock Materials on Microstructure of 304L and 316L Stainless Steel Produced by Additive Manufacturing , 2018, Metallurgical and Materials Transactions A.

[63]  J. S. Zuback,et al.  Additive manufacturing of metallic components – Process, structure and properties , 2018 .

[64]  G. B. Olson,et al.  Characterization of nano-scale oxides in austenitic stainless steel processed by powder bed fusion , 2018, Scripta Materialia.

[65]  S. Biamino,et al.  Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition. , 2018, Journal of visualized experiments : JoVE.

[66]  A. Zadi-Maad,et al.  Additive manufacturing for steels: a review , 2018 .

[67]  Gregor Jacob,et al.  Prediction of Solidification Phases in Cr-Ni Stainless Steel Alloys Manufactured by Laser Based Powder Bed Fusion Process , 2018 .

[68]  Du-Rim Eo,et al.  Inclusion evolution in additive manufactured 316L stainless steel by laser metal deposition process , 2018, Materials & Design.

[69]  Luca Iuliano,et al.  A literature review of powder-based electron beam melting focusing on numerical simulations , 2018 .

[70]  X. Lou,et al.  Oxide inclusions in laser additive manufactured stainless steel and their effects on impact toughness and stress corrosion cracking behavior , 2018 .

[71]  S. Biamino,et al.  An investigation on the effect of powder recycling on the microstructure and mechanical properties of AISI 316L produced by Directed Energy Deposition , 2019, Materials Science and Engineering: A.

[72]  S. Biamino,et al.  How the nozzle position affects the geometry of the melt pool in directed energy deposition process , 2019, Powder Metallurgy.

[73]  J. Schoenung,et al.  On the evolution of microstructure and defect control in 316L SS components fabricated via directed energy deposition , 2019, Materials Science and Engineering: A.

[74]  S. Biamino,et al.  Microstructural Evolution of Post-Processed Hastelloy X Alloy Fabricated by Laser Powder Bed Fusion , 2019, Materials.

[75]  W. Woo,et al.  Microstructure and mechanical characteristics of multi-layered materials composed of 316L stainless steel and ferritic steel produced by direct energy deposition , 2019, Journal of Alloys and Compounds.

[76]  A. Röttger,et al.  Processing of gas-nitrided AISI 316L steel powder by laser powder bed fusion – Microstructure and properties , 2019 .

[77]  J. Pang,et al.  Characterisation of porosity, density, and microstructure of directed energy deposited stainless steel AISI 316L , 2019, Additive Manufacturing.

[78]  S. Biamino,et al.  Laser Powder Bed Fusion of Inconel 718: Residual Stress Analysis Before and After Heat Treatment , 2019 .

[79]  Wang Zhandong,et al.  Laser metal deposition as repair technology for 316L stainless steel: Influence of feeding powder compositions on microstructure and mechanical properties , 2019, Optics & Laser Technology.

[80]  S. Biamino,et al.  Application of Directed Energy Deposition-Based Additive Manufacturing in Repair , 2019, Applied Sciences.

[81]  J. Schoenung,et al.  Improving build quality in Directed Energy Deposition by cross-hatching , 2019, Materials Science and Engineering: A.

[82]  J. Hochhalter,et al.  Enhancement in fatigue performance of metastable austenitic stainless steel through directed energy deposition additive manufacturing , 2019, Materials & Design.

[83]  S. Biamino,et al.  Critical Features in the Microstructural Analysis of AISI 316L Produced By Metal Additive Manufacturing , 2020, Metallography, Microstructure, and Analysis.

[84]  Moataz M. Attallah,et al.  Laser powder bed fusion of a Zr-alloy: Tensile properties and biocompatibility , 2020 .

[85]  Tao Meng,et al.  Microstructure and elevated temperature mechanical properties of IN718 alloy fabricated by laser metal deposition , 2020 .

[86]  P. Fino,et al.  Microstructure and Mechanical Performance of Ti–6Al–4V Lattice Structures Manufactured via Electron Beam Melting (EBM): A Review , 2020, Acta Metallurgica Sinica (English Letters).

[87]  Ji-cai Feng,et al.  Development and characterization of 316L/Inconel625 functionally graded material fabricated by laser direct metal deposition , 2020 .

[88]  D. Manfredi,et al.  The role of texturing and microstructure evolution on the tensile behavior of heat-treated Inconel 625 produced via laser powder bed fusion , 2020 .

[89]  M. Polański,et al.  The influence of laser engineered net shaping (LENS™) technological parameters on the laser deposition efficiency and properties of H13 (AISI) steel , 2020 .

[90]  S. Biamino,et al.  An investigation on the effect of deposition pattern on the microstructure, mechanical properties and residual stress of 316L produced by Directed Energy Deposition , 2020, Materials Science and Engineering: A.

[91]  Del Guercio Giuseppe,et al.  Microstructure and Mechanical Performance of Ti-6Al-4V Lattice Structures Manufactured via Electron Beam Melting (EBM): A Review , 2020 .

[92]  S. Biamino,et al.  Directed Energy Deposition of 316L Steel: Effect of Type of Powders and Gas Related Parameters , 2020 .

[93]  The role of Directed Energy Deposition atmosphere mode on the microstructure and mechanical properties of 316L samples , 2020 .