Development of laser AM process to repair damaged super duplex stainless steel components

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Ahmad, Abdul and Xirouchakis, Paul and Pearson, Alastair and Brownlie, Frazer and Gorash, Yevgen (2025) Development of laser AM process to repair damaged super duplex stainless steel components. Sustainability, 17 (12). 5438. ISSN 2071-1050 (https://doi.org/10.3390/su17125438)

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Abstract

The escalating demands of industrial applications, particularly those involving severe wear, temperature, and corrosive environments, present significant challenges for the long-term strength of critical components, often fabricated from high-value materials such as super duplex stainless steel alloys. Super duplex can withstand the corrosive environment (in particular, crevice corrosion and pitting damage) and maintain mechanical integrity sufficient for high-pressure pumping applications such as seawater injection and crude oil. Conventional repair methodologies frequently result in component rejection due to process-induced distortions or detrimental phase transformations, contributing to substantial material waste and hindering the adoption of circular economy principles. This research addresses this issue by developing and validating a novel repair process utilizing laser metal deposition (LMD) additive manufacturing. The research focuses on establishing optimized process parameters to ensure the salvaging and restoration of damaged super duplex components while preserving their requisite mechanical integrity and corrosion resistance, in accordance with industry standards. Comprehensive characterization, including microstructural analysis, chemical composition verification, hardness profiling, and mechanical fatigue testing, confirms the efficacy of the LMD repair process. This work demonstrates the potential for extending the service life of critical components, thereby promoting resource efficiency and contributing to a more sustainable and resilient industrial paradigm.

ORCID iDs

Ahmad, Abdul ORCID logoORCID: https://orcid.org/0000-0001-6276-3255, Xirouchakis, Paul ORCID logoORCID: https://orcid.org/0000-0002-3041-3645, Pearson, Alastair, Brownlie, Frazer ORCID logoORCID: https://orcid.org/0000-0002-3087-090X and Gorash, Yevgen ORCID logoORCID: https://orcid.org/0000-0003-2802-7814;
CORE (COnnecting REpositories)