Feasibility study of wire arc additive manufactured P91 steel by cold metal transfer deposition

The objective of this study was to analyze and evaluate the feasibility of utilizing Wire Arc Additive Manufacturing (WAAM) technology for the constructing components made from P91 steel, which is widely used material for high-temperature applications. The utilization of the Cold Metal Transfer (CMT) method enables the deposition of thin steel walls by virtue of its low heat input. Samples collected from the deposited wall have been tested in two different microstructural conditions, in the as-built (AB) condition and in a normalized and tempered (NT) condition. The latter condition is the microstructural state commonly employed for producing components used in power plants. This post-deposition heat treatments (PDHT) comprise a normalization process conducted at 1050 C-degrees for 40 min, followed by a tempering step at 760 C-degrees for 2 h. The results of mechanical testing and microstructural characterization were then compared against the established standards for commercial P91 steel. SEM-EDAX, XRD, and EBSD analyses were employed to conduct a comprehensive microstructural examination of the samples. The hardness of the AB samples ranged from 384 to 439 HV, while the NT samples had a hardness range of 205 to 223 HV. In terms of tensile strength, the AB samples demonstrated a range of 1064 to 1266 MPa, whereas the NT samples exhibited a range of 635 to 626 MPa. These results were found to be consistent with the observed strong texture and grain orientations in the {001} and {111} planes, as revealed by the EBSD analysis. The NT components demonstrated significant strength, ductility, hardness, and toughness compared to the specified ASTM standards. Based on the test performance and feasibility criteria, this process has significant potential as an additive manufacturing method suitable for complex boiler components.