| Abstract Scope |
Wire-Arc Directed Energy Deposition (DED) is an additive manufacturing process that enables the efficient fabrication of large-scale metallic components due to its high deposition rates and compatibility with existing arc-welding infrastructure. This work presents the ongoing development of wire-arc DED of high-strength steels (HSS), focusing on the initial process-development stage and the planned research pathway. The study is motivated by the growing demand for HSS in structural applications such as defense systems and subsea oil and gas tooling and connectors, where high strength, toughness, and manufacturing efficiency are critical requirements.
The project encompasses the evaluation of high-strength filler metals in both metal-cored and solid-wire forms, optimization of deposition parameters and thermal management strategies, and comparison of as-built and post-deposition heat-treated conditions. Performance targets include yield strength exceeding 100 ksi while maintaining adequate ductility, impact toughness, and process productivity. Current efforts are centered on establishing robust deposition conditions, selecting suitable process variants, and generating the experimental foundation for subsequent microstructural characterization, mechanical testing, and heat-treatment optimization.
Future activities will include the assessment of residual stresses, proof-of-concept component fabrication, and the development of productivity-enhancement strategies, including active cooling approaches to reduce idle time while maintaining interpass temperature control. The work outlines a pathway toward the implementation of high-performance wire-arc DED of HSS for industrially relevant applications. |