Microstructural Evolution, Mechanical and Electrochemical Performance of Duplex Stainless Steel Fabricated by Wire Arc Additive Manufacturing with ER2209 Filler Wire

This study examines the dependent relationship between microstructure, mechanical properties, and corrosion performance on the wire arc additive manufactured (WAAM) ER2209 duplex stainless steel (DSS). DSS is renowned for its corrosion resistance and mechanical strength, making it favorable for various applications. This study uses the gas metal arc welding (GMAW)‐ based WAAM technique to fabricate the wall structure using ER2209 DSS filler wire. Fine, equiaxed dendrites are formed along the build direction, with the austenite phase exceeding 70% due to the repeated heating and slow cooling inherent to WAAM process. X‐ray diffraction (XRD) confirms no brittle intermetallic phases. The results shows that varying austenite‐ferrite fractions significantly influences the anisotropy in mechanical properties between build and deposit directions. Along the build direction, the varying phase fraction causes difference in hardness of 19.59 HV0.3 and tensile strength of 20 MPa. The maximum tensile strength (787.08 MPa) is observed in the deposit direction, with a 52 MPa difference between the build and deposit directions. Tafel and EIS measurements indicated that WAAM samples corrosion resistance was almost close to wrought 2205 DSS. This study highlights WAAM's potential for defect‐free DSS parts and suggests post‐heat treatment to optimize microstructure and mechanical properties. Duplex stainless steel (DSS) is renowned for its corrosion resistance and tensile properties. Wire arc additive manufacturing (WAAM) is used to fabricate a wall structure with ER2209 filler wire. Fine, equiaxed dendrites are formed along the build direction, with over 70% austenite due to repeated heating and slow cooling during the WAAM process.