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<p>SS309L stainless steel is commonly used in industries such as aerospace, marine, and energy due to its excellent resistance to high temperatures and corrosion, as well as its superior mechanical strength. This makes it an ideal candidate for fabrication using wire arc additive manufacturing (WAAM), a technology known for its high deposition rates and cost-effectiveness. However, optimizing process parameters is essential to enhance the mechanical properties, microstructure, and physical characteristics of SS309L when fabricated via WAAM. In this study, response surface methodology (RSM) was applied to optimize bead width and bead height in WAAM-fabricated SS309L. The optimization was conducted by varying welding current (100-150&#xa0;A), voltage (10-20&#xa0;V), and travel speed (0.1-0.3&#xa0;m/min). A multi-layered wall was constructed using the optimized parameters (135&#xa0;A, 16&#xa0;V, and 0.1&#xa0;m/min) for subsequent analysis of mechanical properties and microstructure, as well as physical examination and finite element analysis (FEA). The mechanical tests showed that the top section of the fabricated wall achieved an ultimate tensile strength (UTS) of 561.81&#xa0;MPa, a yield strength of 435.63&#xa0;MPa, and an elongation rate of 41.2%. The bottom section showed a UTS of 469.73&#xa0;MPa with 45.6% elongation. The middle section exhibited a maximum compressive strength of 984.2&#xa0;MPa. Microstructural analysis using x-ray diffraction (XRD), electron backscatter diffraction (EBSD), and scanning electron microscopy (SEM) confirmed that the top section contained fine-grained structures, while the bottom section exhibited coarser features. The porosity of the material was exceptionally low at 0.0081%. FEA simulations confirmed the experimental results, validating stress and deformation patterns. The study provides a comprehensive methodology for optimizing SS309L WAAM structures for high-performance industrial applications.</p> Graphical Abstract <p></p>

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Multi-scale Optimization and Computational Validation for Enhancing the Microstructure, Mechanical Properties, and Physical Performance of Wire Arc Additive Manufacturing-Fabricated SS309L Stainless Steel

  • 期刊论文

  • 发表日期：

    2025年9月2日

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  • S. Tamil Prabakaran,
  • Saravanakumar Sengottaiyan,
  • D. Yogaraj,
  • V. S. Shaisundaram

摘要

SS309L stainless steel is commonly used in industries such as aerospace, marine, and energy due to its excellent resistance to high temperatures and corrosion, as well as its superior mechanical strength. This makes it an ideal candidate for fabrication using wire arc additive manufacturing (WAAM), a technology known for its high deposition rates and cost-effectiveness. However, optimizing process parameters is essential to enhance the mechanical properties, microstructure, and physical characteristics of SS309L when fabricated via WAAM. In this study, response surface methodology (RSM) was applied to optimize bead width and bead height in WAAM-fabricated SS309L. The optimization was conducted by varying welding current (100-150 A), voltage (10-20 V), and travel speed (0.1-0.3 m/min). A multi-layered wall was constructed using the optimized parameters (135 A, 16 V, and 0.1 m/min) for subsequent analysis of mechanical properties and microstructure, as well as physical examination and finite element analysis (FEA). The mechanical tests showed that the top section of the fabricated wall achieved an ultimate tensile strength (UTS) of 561.81 MPa, a yield strength of 435.63 MPa, and an elongation rate of 41.2%. The bottom section showed a UTS of 469.73 MPa with 45.6% elongation. The middle section exhibited a maximum compressive strength of 984.2 MPa. Microstructural analysis using x-ray diffraction (XRD), electron backscatter diffraction (EBSD), and scanning electron microscopy (SEM) confirmed that the top section contained fine-grained structures, while the bottom section exhibited coarser features. The porosity of the material was exceptionally low at 0.0081%. FEA simulations confirmed the experimental results, validating stress and deformation patterns. The study provides a comprehensive methodology for optimizing SS309L WAAM structures for high-performance industrial applications.

Graphical Abstract