In-situ directed energy deposition of Al based low density steel for automotive applications

Abstract This work deals with the fabrication of one low density steel by mixing AISI S2 tool steel and AlSi10Mg powders using powder-based directed energy deposition (P-DED) technique. Two approaches of mixing powders were compared-continuous mixing during the process (in-situ) and mixing the powder prior to the process (premixed). The P-DED sample was characterised by a variety of techniques such as optical microscopy, scanning electron microscopy, electron backscatter diffraction, X-ray diffraction, and hardness measurement. Our findings demonstrate the successful achievement of steel with a 8 wt. % AlSi10Mg addition when two dissimilar powders are premixed, resulting in approximately 12% reduction in the density of S2 steel. Optimizing the powder feed rate and the ratio of AlSi10Mg powder contribute to an improvement of printability, eliminating materials separation, leading to a homogenous deposited part. Compared to the in-situ mixing case, the premixed process within the current process window generates a more homogeneous microstructure consisting of three phases: Ferrite, Fe3Al and Fe3AlC carbide. Whereas, the in-situ sample exhibits only two phases Ferrite and Fe3Al. The hardness of the premixed sample is found to be slightly higher compared to the in-situ sample.