Effects of processing conditions on the solidification and heat-affected zone of 309L stainless steel claddings on carbon steel using wire-directed energy deposition

Directed energy deposition and laser cladding technologies are suitable advanced manufacturing techniques for applying corrosion-resistant claddings to large carbon steel components. In this work, we clad 309L stainless wire onto substrates examine the effects of processing parameters (laser power travel speed) on metallurgical bonding microstructures. Wire dripping defects correlate excessive heat input, while cracking, stubbing delamination linked with insufficient input. Spectroscopic scans weld microstructure show amount base metal mixing in is a function number layers. first layer, diluted ranging from 1.7 45.6 %; dramatically decreases second layer (0–8.6 %), promoting primary ferrite solidification, which solidification cracking susceptibility. Martensite forms heat-affected zone high cooling rates associated processing. Subsequent passes temper martensite diffuses substrate into layer. Cladding two or more layers beneficial mitigating defects, lowering dilution, producing highly alloyed surface corrosion protection.