Grain size manipulation by wire laser direct energy deposition of 316L with ultrasonic assistance

The epitaxial growth of coarse and columnar grain structures along the build direction of additive manufactured metals is a usual phenomenon. As a result, as-built components often exhibit pronounced anisotropic mechanical properties, reduced ductility, and, hence, a high cracking susceptibility. To enhance the mechanical properties and processability of additive manufactured parts, the formation of equiaxed and fine grained structures is thought to be most beneficial. In this study, the potential of grain refinement by ultrasonic excitation of the melt pool during laser wire additive manufacturing has been investigated. An ultrasound system was developed and integrated in a laser wire deposition machine. AISI 316L steel was used as a substrate and feedstock material. A conversion of coarse, columnar grains (dm = 284.5 μm) into fine, equiaxed grains (dm = 130.4 μm) and a weakening of typical <100>-fiber texture with increasing amplitude were verified by means of light microscopy, scanning electron microscopy, and electron backscatter diffraction analysis. It was demonstrated that the degree of grain refinement could be controlled by the regulation of ultrasound amplitude. No significant changes in the dendritic structure have been observed. The combination of sonotrode/melt pool direct coupling and the laser wire deposition process represents a pioneering approach and promising strategy to investigate the influence of ultrasound on grain refinement and microstructural tailoring.