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<p>Wire arc additive manufacturing (WAAM) is a promising technique for fabricating large-scale, high-performance metal components. This study focuses on the fabrication of boiler-grade SS308L stainless steel walls using WAAM and evaluates their fracture toughness through single-edge notch bend (SENB) testing, a method for determining crack resistance. The measured fracture toughness of WAAM-fabricated SS308L reached 176.56&#xa0;MPa√m, showing an 8.4% improvement over conventionally wrought (WR) SS308L (162.81&#xa0;MPa√m). Detailed microstructural analysis was conducted to assess variations across build regions and their influence on crack resistance. Crack propagation behavior was further analyzed using generalized finite element method (GFEM), a numerical simulation technique for modeling fracture mechanics. The numerical predictions closely matched experimental outcomes, with deviations under 2%. The novelty of this work lies in the integrated experimental and numerical investigation of toughness behavior in WAAM-fabricated boiler-grade stainless steel, supported by microstructural correlation. The findings demonstrate the suitability of WAAM for high-integrity pressure components in thermal power and boiler application.</p>

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Microstructural Evolution and Comparative Crack Toughness Analysis of Boiler-Grade Stainless Steel 308L Processed by Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月10日

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  • Dhinakaran Veeman,
  • Pechimuthu Arumugaperumal,
  • Kanishkaa Jeevaraj,
  • Mohith Mohan Das,
  • Bhavankumar Padmanaban,
  • Micheal Agnelo Browne,
  • Mohan Kumar Subramaniyan

摘要

Wire arc additive manufacturing (WAAM) is a promising technique for fabricating large-scale, high-performance metal components. This study focuses on the fabrication of boiler-grade SS308L stainless steel walls using WAAM and evaluates their fracture toughness through single-edge notch bend (SENB) testing, a method for determining crack resistance. The measured fracture toughness of WAAM-fabricated SS308L reached 176.56 MPa√m, showing an 8.4% improvement over conventionally wrought (WR) SS308L (162.81 MPa√m). Detailed microstructural analysis was conducted to assess variations across build regions and their influence on crack resistance. Crack propagation behavior was further analyzed using generalized finite element method (GFEM), a numerical simulation technique for modeling fracture mechanics. The numerical predictions closely matched experimental outcomes, with deviations under 2%. The novelty of this work lies in the integrated experimental and numerical investigation of toughness behavior in WAAM-fabricated boiler-grade stainless steel, supported by microstructural correlation. The findings demonstrate the suitability of WAAM for high-integrity pressure components in thermal power and boiler application.