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Large-scale wire arc additive manufacturing of duplex stainless steel: Comprehensive insights into microstructure and mechanical behavior.

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Title: Large-scale wire arc additive manufacturing of duplex stainless steel: Comprehensive insights into microstructure and mechanical behavior.
Authors: Mahey, Vishal1 (AUTHOR), Johnson, Grant A.2 (AUTHOR), Burad, Prayag1 (AUTHOR), Chulist, Robert3 (AUTHOR), Collins, Peter C.2 (AUTHOR), Roy, Sougata1 (AUTHOR) sroy@iastate.edu
Source: Materials Science & Engineering: A. Jun2026, Vol. 963, pN.PAG-N.PAG. 1p.
Subjects: Duplex stainless steel, Mechanical behavior of materials, Microstructure, Electric welding, Porosity, Tensile tests, Phase transitions, Anisotropy
Abstract: In the present study, large-scale Wire Arc Additive Manufacturing (WAAM) of duplex stainless steel (DSS) 2209 was investigated. The research seeks to understand microstructural evolution, mechanical properties, and phase distributions along the scanning and build directions. The results demonstrated remarkable uniformity in microstructure and microhardness properties across the build height (top, middle, and bottom regions) and scan direction (edge and central regions), with notable deviations observed in the near-substrate region. The observed uniformity is attributed to optimized process conditions, interlayer reheating during successive depositions, and controlled interlayer temperature. Edge samples exhibited slightly higher porosity than central samples; however, porosity remained consistent along the build height. The near-substrate region displayed increased porosity and finer grains compared to the rest of the wall. EBSD analysis revealed austenite phase content to be uniform across the build height and scan direction, aside from the near-substrate region, which showed higher austenite content. The microhardness values were consistent across the wall, except for the near-substrate region, where a lower hardness was observed due to the higher austenite content in that region. Tensile testing indicated higher strength and lower ductility in horizontal samples compared to vertical samples, with no significant differences along the build height, highlighting the role of sample orientation in mechanical properties. While the overall microstructure and properties exhibited macroscopic uniformity, higher magnification analysis revealed localized variations in austenite morphology between edge and central regions, although the differences did not result in substantial property variations. The observed uniformity in structure and properties, with variations confined to the initial near-substrate region, highlights the potential and reliability of the WAAM process for fabricating large-scale DSS components with minimal variability, making it suitable for industrial-scale applications. • Largest WAAM-fabricated DSS 2209 wall till date with comprehensive microstructure-property relationship study. • Macroscopic uniformity with localized microscopic differences in microstructure and phase distribution. • Tensile anisotropy between horizontal and vertical samples linked to grain alignment and deformation mechanisms. [ABSTRACT FROM AUTHOR]
Copyright of Materials Science & Engineering: A is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
An: 193247266
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PubTypeId: academicJournal
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  Data: Large-scale wire arc additive manufacturing of duplex stainless steel: Comprehensive insights into microstructure and mechanical behavior.
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  Data: <searchLink fieldCode="AR" term="%22Mahey%2C+Vishal%22">Mahey, Vishal</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Johnson%2C+Grant+A%2E%22">Johnson, Grant A.</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Burad%2C+Prayag%22">Burad, Prayag</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Chulist%2C+Robert%22">Chulist, Robert</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Collins%2C+Peter+C%2E%22">Collins, Peter C.</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Roy%2C+Sougata%22">Roy, Sougata</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> sroy@iastate.edu</i>
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  Data: <searchLink fieldCode="DE" term="%22Duplex+stainless+steel%22">Duplex stainless steel</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+welding%22">Electric welding</searchLink><br /><searchLink fieldCode="DE" term="%22Porosity%22">Porosity</searchLink><br /><searchLink fieldCode="DE" term="%22Tensile+tests%22">Tensile tests</searchLink><br /><searchLink fieldCode="DE" term="%22Phase+transitions%22">Phase transitions</searchLink><br /><searchLink fieldCode="DE" term="%22Anisotropy%22">Anisotropy</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: In the present study, large-scale Wire Arc Additive Manufacturing (WAAM) of duplex stainless steel (DSS) 2209 was investigated. The research seeks to understand microstructural evolution, mechanical properties, and phase distributions along the scanning and build directions. The results demonstrated remarkable uniformity in microstructure and microhardness properties across the build height (top, middle, and bottom regions) and scan direction (edge and central regions), with notable deviations observed in the near-substrate region. The observed uniformity is attributed to optimized process conditions, interlayer reheating during successive depositions, and controlled interlayer temperature. Edge samples exhibited slightly higher porosity than central samples; however, porosity remained consistent along the build height. The near-substrate region displayed increased porosity and finer grains compared to the rest of the wall. EBSD analysis revealed austenite phase content to be uniform across the build height and scan direction, aside from the near-substrate region, which showed higher austenite content. The microhardness values were consistent across the wall, except for the near-substrate region, where a lower hardness was observed due to the higher austenite content in that region. Tensile testing indicated higher strength and lower ductility in horizontal samples compared to vertical samples, with no significant differences along the build height, highlighting the role of sample orientation in mechanical properties. While the overall microstructure and properties exhibited macroscopic uniformity, higher magnification analysis revealed localized variations in austenite morphology between edge and central regions, although the differences did not result in substantial property variations. The observed uniformity in structure and properties, with variations confined to the initial near-substrate region, highlights the potential and reliability of the WAAM process for fabricating large-scale DSS components with minimal variability, making it suitable for industrial-scale applications. • Largest WAAM-fabricated DSS 2209 wall till date with comprehensive microstructure-property relationship study. • Macroscopic uniformity with localized microscopic differences in microstructure and phase distribution. • Tensile anisotropy between horizontal and vertical samples linked to grain alignment and deformation mechanisms. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials Science & Engineering: A is the property of Elsevier B.V. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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      – Type: doi
        Value: 10.1016/j.msea.2026.150232
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      – Code: eng
        Text: English
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        PageCount: 1
        StartPage: N.PAG
    Subjects:
      – SubjectFull: Duplex stainless steel
        Type: general
      – SubjectFull: Mechanical behavior of materials
        Type: general
      – SubjectFull: Microstructure
        Type: general
      – SubjectFull: Electric welding
        Type: general
      – SubjectFull: Porosity
        Type: general
      – SubjectFull: Tensile tests
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      – SubjectFull: Phase transitions
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      – SubjectFull: Anisotropy
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      – TitleFull: Large-scale wire arc additive manufacturing of duplex stainless steel: Comprehensive insights into microstructure and mechanical behavior.
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              M: 06
              Text: Jun2026
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              Y: 2026
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