Evaluation on Mechanical and Metallurgical properties of Wire Arc Additive Manufactured ER 2209 Duplex Stainless Steel for Automotive and Marine applications

The advancement of wire-arc additive manufacturing (WAAM) presents a significant opportunity to revolutionize the production of automotive components through the fabrication of complex, high-performance structures. This study specifically investigates the metallurgical, mechanical, and corrosion properties of WAAM-fabricated ER2209 duplex stainless steel structures, known for their superior mechanical properties, excellent corrosion resistance, and favorable tribological behavior. The research aims to optimize WAAM process parameters to achieve high-quality deposition of ER2209, ensuring structural integrity and performance suitable for both marine and various automotive applications. Microstructural analysis of the produced samples revealed the alloy’s dual-phase nature, with roughly equal amounts of ferrite and austenite phases uniformly mixed across the layers of deposition. This balanced microstructure contributes to the alloy’s excellent mechanical properties. Yield strength, elongation, and ultimate tensile strength derived from tensile testing of samples in both the build direction and travel direction were found to be on par with those of the wrought alloy, indicating that WAAM does not compromise the inherent mechanical integrity of ER2209 duplex stainless steel. Electrochemical corrosion testing was conducted to evaluate the suitability of WAAM ER2209 for marine environments, where corrosion resistance is critical. The results showed a significant corrosion rate of 0.032 mm/year, demonstrating the alloy’s capability to withstand marine exposure effectively. Additionally, linear reciprocating wear test indicated a specific wear rate of 7.76 × 10^-04 mm/Nm, highlighting the material’s robust tribological performance. The findings indicate that WAAM can produce high-quality ER2209 components that meet the stringent mechanical and corrosion resistance requirements of these industries, supporting its broader adoption. By harnessing CMT-based WAAM, manufacturers can achieve efficient and cost-effective production of complex, high-performance stainless steel structures, promoting innovation and sustainability in automotive and marine engineering.