An example of a Super Duplex Stainless Steel casting that can be
metal 3D printed using WAM. Image credit: AML3D
In the advanced manufacturing industry, a breakthrough
in material science is poised to revolutionise the landscape of tough
applications.
Researchers at the School of
Mechanical & Mining Engineering at the University of Queensland and The
School of Electrical and Mechanical Engineering at the University of Adelaide,
in collaboration with AML3D’s Chief Technology Officer Andy Sales, have uncovered insights
into the capabilities of Wire Additive
Manufacturing (WAM) in producing
Super Duplex Stainless Steel (SDSS) components.
The fatigue properties of SDSS, a
steel alloy known for its exceptional strength and corrosion resistance, were
put to the test under rigorous examination using the innovative WAM technique.
This method, which involves layer-by-layer metal deposition, showcased the
potential to fabricate robust structures with unprecedented durability.
The research, focused on assessing
Fatigue Crack Growth (FCG) characteristics, yielded promising results.
Key findings revealed that the fatigue
properties of SDSS, manufactured via WAM, exhibited remarkable isotropic
behaviour, meaning similar performance was observed in both longitudinal and
transverse directions relative to the deposition direction.
Furthermore, the study shed light on
the influence of manufacturing parameters
on crack growth behaviour. Residual stresses induced during the rapid cooling
process inherent to WAM were identified as a significant factor affecting crack
growth dynamics.
Understanding these nuances opens
avenues for optimizing component design and fabrication processes to enhance
fatigue resistance and longevity.
The implications of these findings
extend far beyond the realm of academia. With the potential to mitigate
fatigue-related failures in critical applications, such as marine and offshore
structures, the utilization of WAM-fabricated SDSS components heralds a new era
of innovation in engineering and construction.
Although additional research is
necessary to confirm these findings under various printing conditions, the
foundation established by this study highlights the significant potential of
SDSS to enhance the strength and effectiveness of structural materials.