Comparative analysis of the mechanical properties and environmental performance of additively manufactured 316LSi stainless steel via directed energy deposition
Additive Manufacturing (AM) has emerged as a significant method in manufacturing, enabling innovations in advanced production techniques and material utilisation. Among its various techniques, Directed Energy Deposition (DED), including Wire Arc DED (WA-DED) and Wire Laser DED (W-LDED) have proven effective for manufacturing high-performance stainless steel components, such as 316LSi, valued for their corrosion resistance and mechanical strength. However, the mechanical properties and environmental impacts of these processes remain underexplored. Recognizing the gap in knowledge, this study provides a comparative analysis of their mechanical and environmental impacts.
Experimental characterization reveals that W-LDED components exhibit a 23% higher tensile strength and 7% greater hardness compared to WA-DED. Microstructural analysis reveals that WA-DED produces coarser grains with higher porosity, while W-LDED yields finer, closely spaced dendrites, enhancing mechanical performance. A life cycle assessment (LCA) using the ReCiPe 2016 v1.1 Midpoint (H) method quantified the climate change impact of both processes in terms of kgCO2eq per functional unit, revealing WA-DED’s 56% lower emissions compared to W-LDED, mainly driven by its higher energy efficiency.
The findings highlight the trade offs between WA-DED and W-LDED, providing actionable information for the selection of DED processes that optimise performance and sustainability priorities. This work provides insight into the understanding of DED processes for various industrial applications and contributes to advances in additive manufacturing
