Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries
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...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-07-01
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| Series: | Additive Manufacturing Letters |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2772369025000404 |
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| author | Jun Wang Mark Taylor Chenglei Diao Ed Pickering Jian Qin Yao Lu Sonia Martins Meco Jialuo Ding Stewart Williams |
| author_facet | Jun Wang Mark Taylor Chenglei Diao Ed Pickering Jian Qin Yao Lu Sonia Martins Meco Jialuo Ding Stewart Williams |
| author_sort | Jun Wang |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-a0d3dcfdae73477e8f25728b7457c1b0 |
| institution | Kabale University |
| issn | 2772-3690 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Additive Manufacturing Letters |
| spelling | doaj-art-a0d3dcfdae73477e8f25728b7457c1b02025-08-21T04:17:56ZengElsevierAdditive Manufacturing Letters2772-36902025-07-011410030710.1016/j.addlet.2025.100307Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometriesJun Wang0Mark Taylor1Chenglei Diao2Ed Pickering3Jian Qin4Yao Lu5Sonia Martins Meco6Jialuo Ding7Stewart Williams8Welding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UK; Corresponding author.Department of Materials / Henry Royce Institute, The University of Manchester, Manchester M13 9PL, UKWelding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UKDepartment of Materials / Henry Royce Institute, The University of Manchester, Manchester M13 9PL, UKWelding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UKWelding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UKWelding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UKWelding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UKWelding and Additive Manufacturing Centre, Cranfield University, Cranfield MK43 0AL, UKHybrid 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.http://www.sciencedirect.com/science/article/pii/S2772369025000404300 m ultra-high-strength steelWire-based direct energy depositionPost heat treatmentCracking preventionmaterial performance |
| spellingShingle | Jun Wang Mark Taylor Chenglei Diao Ed Pickering Jian Qin Yao Lu Sonia Martins Meco Jialuo Ding Stewart Williams Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries Additive Manufacturing Letters 300 m ultra-high-strength steel Wire-based direct energy deposition Post heat treatment Cracking prevention material performance |
| title | Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries |
| title_full | Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries |
| title_fullStr | Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries |
| title_full_unstemmed | Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries |
| title_short | Insights into crack prevention and property improvement for additively manufactured ultra-high-strength steel structures with complex geometries |
| title_sort | insights into crack prevention and property improvement for additively manufactured ultra high strength steel structures with complex geometries |
| topic | 300 m ultra-high-strength steel Wire-based direct energy deposition Post heat treatment Cracking prevention material performance |
| url | http://www.sciencedirect.com/science/article/pii/S2772369025000404 |
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