Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries

IF 4.7 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters Pub Date : 2025-07-01 DOI:10.1016/j.addlet.2025.100307

Jun Wang , Mark Taylor , Chenglei Diao , Ed Pickering , Jian Qin , Yao Lu , Sonia Martins Meco , Jialuo Ding , Stewart Williams

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Abstract

Hybrid wire-arc directed energy deposition (WDED), in which complex features are deposited onto a forged base, offers a cost-effective solution for manufacturing geometrically complex ultra-high-strength steel components, particularly for aerospace applications. However, cracking at the base forging/build interface during post-build heat treatment limits its widespread application. This study investigates the underlying causes of interfacial cracking, highlighting microstructural inhomogeneity, elemental segregation and transformation stresses as likely key contributing factors. A modified three-step post-build heat treatment incorporating a normalisation step was developed to mitigate some of these issues. The optimised process successfully suppressed cracking by refining prior-austenite grains before the application of a conventional quenching step. This enhanced tensile performance beyond AMS6419K standards, supporting the industrial implementation of hybrid WDED in aerospace structures.

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复杂几何形状的增材制造超高强度钢结构的裂缝预防和性能改进

混合线弧定向能沉积（WDED）技术将复杂的特征沉积在锻造底座上，为制造几何形状复杂的超高强度钢部件，特别是航空航天应用，提供了一种经济高效的解决方案。然而，在锻后热处理过程中，基锻/铸模界面的开裂限制了其广泛应用。本研究探讨了界面开裂的根本原因，强调微观结构的不均匀性、元素偏析和相变应力可能是主要的影响因素。一种改进的三步后热处理纳入了正火步骤，以减轻这些问题。优化后的工艺在应用常规淬火步骤之前，通过细化先验奥氏体晶粒成功地抑制了裂纹。这种增强的拉伸性能超出了AMS6419K标准，支持混合WDED在航空航天结构中的工业实施。

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