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<p>The increasing demand for high-performance stainless steel components in structural applications necessitates a deeper understanding of their fracture resistance, especially when fabricated through emerging manufacturing techniques. This study addresses the limited knowledge of the fracture behavior of SS304 produced via wire arc additive manufacturing (WAAM) compared to its conventional wrought counterpart. Single-edge notch bend (SENB) tests were conducted to evaluate the Mode experimentally I stress intensity factor (SIF), revealing that WAAM-fabricated SS304 exhibited a higher SIF of 159.68 MPa·m<sup>1/2</sup>, compared to 147.51 MPa·m<sup>1/2</sup> for wrought SS304, an increase of approximately 8.3%. Microstructural analysis using electron backscatter diffraction (EBSD) and scanning electron microscope (SEM) revealed a mixed columnar-equiaxed dendritic structure and a higher density of high-angle grain boundaries in WAAM specimens, contributing to increased crack resistance. Fractographic analysis further confirmed ductile failure, with localized stress concentrations characterized by dimples and voids. The findings establish a strong correlation between the unique microstructural features induced by the WAAM process and improved fracture toughness, demonstrating WAAM’s potential as a viable method for producing crack-resistant SS304 components.</p>

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Microstructural Features and Correlation of Stress Intensity Factor for Stainless Steel Fabricated Through Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年5月29日

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  • D. Veeman,
  • M. M. Das,
  • B. Padmanaban,
  • M. A. Browne,
  • Subramaniyan Mohan Kumar

摘要

The increasing demand for high-performance stainless steel components in structural applications necessitates a deeper understanding of their fracture resistance, especially when fabricated through emerging manufacturing techniques. This study addresses the limited knowledge of the fracture behavior of SS304 produced via wire arc additive manufacturing (WAAM) compared to its conventional wrought counterpart. Single-edge notch bend (SENB) tests were conducted to evaluate the Mode experimentally I stress intensity factor (SIF), revealing that WAAM-fabricated SS304 exhibited a higher SIF of 159.68 MPa·m1/2, compared to 147.51 MPa·m1/2 for wrought SS304, an increase of approximately 8.3%. Microstructural analysis using electron backscatter diffraction (EBSD) and scanning electron microscope (SEM) revealed a mixed columnar-equiaxed dendritic structure and a higher density of high-angle grain boundaries in WAAM specimens, contributing to increased crack resistance. Fractographic analysis further confirmed ductile failure, with localized stress concentrations characterized by dimples and voids. The findings establish a strong correlation between the unique microstructural features induced by the WAAM process and improved fracture toughness, demonstrating WAAM’s potential as a viable method for producing crack-resistant SS304 components.