Feasibility of manufacturing high-aspect-ratio hollow tubes of SS410 through wire-arc directed energy deposition

Abstract This study reports new observations from the fabrication of high-aspect-ratio hollow tubes of SS410 through wire-arc directed energy deposition (wire-arc DED) process. Characterisation work was performed on a single tube as a function of its build height. The maximum ultimate tensile strength (UTS) of 1372 MPa and maximum yield strength (YS) of 980 MPa were achieved in the middle region of the tube. The highest UTS in the middle was attributed to the low delta ferrite content. The reduction of delta ferrite was found to be linked with the repetitive heating and cooling. In contrast, the top and bottom sections exhibit a substantial presence of delta ferrite, indicating that the cyclic effects were not considerable. Nevertheless, the presence of significant ductility in the bottom region of the component indicated the occurrence of tempering effects. This observation is further supported by the lower levels of local strain observed using KAM mapping. Overall, this work proposes a novel fabrication method for producing hollow sections with superior strength and ductile properties.