Laser Directed Energy Deposition-Based Additive Manufacturing of Fe20Cr5.5AlY from Single Tracks to Bulk Structures: Statistical Analysis, Process Optimization, and Characterization

Laser directed energy deposition (LDED) can be deployed for depositing high-performance materials various engineering applications. Alumina-forming steel is a material that possesses excellent corrosion and oxidation resistance, finding application in the power generation sector. In present work, LDED using powder feeding (LDED-PF) was used to deposit Fe20Cr5.5AlY alloy single-track, multi-track, multi-layer on SS 316L substrate. Response surface methodology (RSM)-based optimization optimize single-track deposition. The relationship between track geometry parameters build rate with LDED-PF processing studied. Further, nonlinear among major process developed an analysis of variance (ANOVA) utilized find significant parameters. multi-track yielded densely clad layers columnar grain structure. presence complex oxide slag Y, Al, Zr layer detected. A micro-hardness 240–285 HV observed layer, hardness 1088–1276 at layer. multi-layered structures showed relative density 99.7% growth average microhardness 242 HV. study paves way dense alumina-forming building components