SDSS 2025

Mechanical Testing and Microstructural Analysis of Wire Laser Metal Deposited Stainless Steel

  • Kyvelou, Pinelopi (Imperial College London / Pinelopi Kyvelou)
  • Hong, Wenxuan (Imperial College London / Pinelopi Kyvelou)
  • Zhang, Ruizhi (Imperial College London / Pinelopi Kyvelou)
  • Gardner, Leroy (Imperial College London / Pinelopi Kyvelou)

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Laser metal deposition (LMD) is a metal 3D printing method that enables the efficient and cost-effective production of large-scale components, rendering it increasingly attractive for civil engineering applications. However, due to the uncertainty regarding the material response and geometric variability of LMD steels, adoption of this manufacturing method in the construction industry is hindered. To address this, a comprehensive experimental investigation into the mechanical properties and microstructural characteristics of LMD plates made from ER 308LSi stainless steel has been carried out and is presented herein. A series of tensile tests and microstructural analyses were conducted on coupons of different thicknesses, printing strategies, surface conditions and orientations to explore the effects of geometric irregularity and material anisotropy. The results indicated minimal geometric irregularity, with both as-built and machined coupons displaying nearly identical mechanical properties. The thinner specimens showed increased strength and stiffness, mainly attributed to their larger grain sizes. Significant anisotropy was observed from the mechanical tests, explained by a strong crystallographic texture observed in the microstructure. Overall, the examined material exhibited good mechanical performance and geometric consistency. Finally, a modelling approach previously developed for WAAM stainless steel was successfully adopted to characterise the anisotropic behaviour of LMD stainless steel in both the elastic and inelastic material ranges. The findings highlight the potential for using LMD in construction, offering a viable alternative for fabricating large-scale metal components of complex geometries.