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<p>This study investigates friction stir processing (FSP) as a post-treatment for wire arc additive manufactured (WAAM) duplex stainless steel ER 2205. Two build configurations, namely a three-layer (S2) and a four-layer (S3) were fabricated and examined in both as-deposited and FSP-treated conditions. The effect of FSP on microstructure, mechanical properties and residual stress was evaluated. Microstructural characterization using optical microscopy, field emission scanning electron microscopy (FESEM), and electron backscatter diffraction (EBSD) revealed significant grain refinement and phase redistribution after FSP. Hardness increased from 263 HV to 353 HV in S2 sample and from 267 HV to 394 HV in S3 sample after processing. Tensile strength improved from 678&#xa0;MPa to 744&#xa0;MPa for S2 sample and from 699&#xa0;MPa to 748&#xa0;MPa for S3 sample, whereas ductility reduced due to restricted plastic flow in the refined microstructure. X-ray diffraction (XRD) indicated the presence of γ-austenite and α-ferrite phases, and peak broadening indicate strain-induced plastic deformation. Residual stress in the S3 sample decreased from 437&#xa0;MPa to 284&#xa0;MPa after FSP. These results reveal that FSP is an effective post-processing technique for improving microstructure, strength, hardness and mitigate residual stress in WAAM-fabricated DSS 2205 components.</p>

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Friction stir processing of WAAM duplex stainless steel: Microstructure, mechanical properties and residual stress

  • 期刊论文

  • 发表日期：

    2026年2月18日

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  • Manish Singh,
  • Ratnesh Kumar Raj Singh,
  • Dheeraj Gupta,
  • Suresh Gain,
  • Pankaj Kumar Singh

摘要

This study investigates friction stir processing (FSP) as a post-treatment for wire arc additive manufactured (WAAM) duplex stainless steel ER 2205. Two build configurations, namely a three-layer (S2) and a four-layer (S3) were fabricated and examined in both as-deposited and FSP-treated conditions. The effect of FSP on microstructure, mechanical properties and residual stress was evaluated. Microstructural characterization using optical microscopy, field emission scanning electron microscopy (FESEM), and electron backscatter diffraction (EBSD) revealed significant grain refinement and phase redistribution after FSP. Hardness increased from 263 HV to 353 HV in S2 sample and from 267 HV to 394 HV in S3 sample after processing. Tensile strength improved from 678 MPa to 744 MPa for S2 sample and from 699 MPa to 748 MPa for S3 sample, whereas ductility reduced due to restricted plastic flow in the refined microstructure. X-ray diffraction (XRD) indicated the presence of γ-austenite and α-ferrite phases, and peak broadening indicate strain-induced plastic deformation. Residual stress in the S3 sample decreased from 437 MPa to 284 MPa after FSP. These results reveal that FSP is an effective post-processing technique for improving microstructure, strength, hardness and mitigate residual stress in WAAM-fabricated DSS 2205 components.