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Projects

A Novel Synergistic Approach of Combining Multiscale DED Processes for Next Generation Hybrid Additive Manufacturing (Funding Agency: US Department of Defense, Research Collaborators: Oak Ridge National Laboratory)

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Duplex stainless steel (DSS) has a biphasic microstructure ideally consisting of 50% austenite (γ) and 50% ferrite (δ). Metal Additive Manufacturing (MAM) has emerged rapidly and received substantial attention from last decade. Wire arc Additive Manufacturing (WAAM) and Laser-Direct Energy Deposition (L-DED) are some of the major DED processes leveraged for depositing metallic material using focused thermal energy resulting into near-net shape products and refurbishment of worn out parts. One of the major challenges in depositing DSS is to understand the complex thermal history which creates difficulty in achieving balanced ferrite-austenite ratio. Consequently, it will impact on the microstructure, mechanical and corrosion properties of deposited parts. In this research, we are working on revealing the major differences in process-microstructure-property relationship due to variation in heat energy and feedstock type to develop strategies for next generation hybrid AM process development in mission critical defense applications.

Research Products:

Conference presentations:

  • Understanding processing-microstructure-property relationships for WAAM and LP-DED in duplex stainless steels, 2023, MS&T Annual Meeting, Columbus, Ohio, USA

  • Gleeble Simulations of Stainless Steels to Understand Correlations between Build Height, Thermal History, Microstructure, and Mechanical Properties in AM, 2024, TMS Annual Meeting, Orlando, Florida, USA.

  • Understanding the effect build orientation and alloying strategy in microstructure and mechanical behavior of laser metal deposited Duplex stainless steel, 2025, TMS Annual Meeting, Las Vegas, Nevada, USA

  • Investigating the Microstructural Consistency and Mechanical Stability of Large-Scale WAAM DSS 2209 for Naval Applications, 2025, TMS Annual Meeting, Las Vegas, Nevada, USA.

  • Microstructure-Property Relationships of Wire-Arc Additively Manufactured 2205 Duplex Stainless Steels, 2025, TMS Annual Meeting, Las Vegas, Nevada, USA

  • A Novel Approach to Develop Functional Duplex Stainless Steel Components via Hybrid Additive Manufacturing, MS & T Annual Meeting, Pittsburgh, PA, USA (2026)

  • Investigating the Large Scale Wire Arc Additive Manufacturability of Super Duplex Stainless Steel: Microstructure and Mechanical Behavior Perspectives, Trends in Welding Research + Additive Manufacturing, Miami, FL, USA (2026)

Journal articles:

  • V. Mahey, G. A. Jhonson, P. Burad, R. Gonzalez-Ojeda, M. J. Quintana, P.C. Collins, S. Roy, “A parametric study of laser-directed energy deposited DSS 2205: Microstructure and mechanical properties perspectives”, JOM, 77, 9295-9307 (2025).

  • V. Mahey, G. Johnson, P. Burad, R. Chulist, P.C. Collins, S. Roy, “Large-Scale Wire Arc Additive Manufacturing of Duplex Stainless Steel: Comprehensive Insights into Microstructure and Mechanical Behavior”, Materials Science & Engineering: A, 963, 150232 (2026).

  • K. R. Ramkumar, P. Burad, V. Mahey, Y. Yamamoto, A. Nycz, R. Wallace, S. Roy, “Process-Driven Roadmap for Depositing Super Duplex Stainless Steel via Wire Arc Additive Manufacturing”, International Journal of Advanced Manufacturing Technology, 143, 5203-5215 (2026).

Research Leads: Prayag Burad and Vishal Mahey
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