Performance of laser metal deposition on hot-rolled stainless steel for hybrid steel structures

The construction sector is increasingly recognising the potential of metal additive manufacturing (AM) for fabricating complex steel details with enhanced performance and reduced resource usage. In the coming years, the application of AM technologies is expected to advance, leading to the development of new structural elements and improved performance of existing ones. This progression involves the integration of conventional construction steel with AM techniques, such as laser metal deposition (LMD), to create hybrid systems that incorporate efficient details. LMD offers the advantage of overcoming size limitations associated with laser powder bed fusion (LPBF) while leveraging its geometric capabilities. In this study, the mechanical behavior of hybrid steel components, fabricated using LMD on AISI316L stainless steel plates, was investigated through an extensive experimental campaign involving 40 samples. Axial tests, fatigue tests, and material characterisation were conducted to evaluate strength criteria and long-term behavior. Results demonstrate that LMD-produced AISI316L exhibits mechanical properties compliant with EN1993's "Design of steel structures" encompassing elastic and plastic behavior. Furthermore, both LMD samples and hybrid specimens exhibit promising fatigue performance, aligning with the highest fatigue detail category (detail category 160) for conventional steel details. • Integration of LMD with conventional steel creates efficient hybrid systems. • Extensive study on LMD hybrid mechanical behavior: axial and fatigue tests. • LMD-produced AISI316L complies with EN1993 requirements. • Good fatigue performance of LMD samples and hybrid specimens.