Investigation of High-Cycle Fatigue Properties of Wire Arc Additive Manufacturing 13Cr4Ni Martensitic Stainless Steel

As one of the widely used materials for hydro turbine runners, 13Cr4Ni martensitic stainless steels (13/4 MSS) manufactured by forging and wire arc additive manufacturing (WAAM), respectively, were selected for high-cycle fatigue tests, and the effects of microstructures and defect characteristics on fatigue mechanism were investigated. The results indicate that compared to the forged 13/4 MSS, the microstructure of the WAAM test piece is very fine, and the martensite units, consequently, are smaller in size. The yield strength and ultimate tensile strength are 685 MPa and 823 MPa for the forged specimen and 850 MPa and 927 MPa for the WAAM specimens, respectively. The fatigue strength of 10(7) cycles at room temperature is 370 MPa for forged specimens and 468 MPa for WAAM specimens. The predominant defect of the forged 13/4 MSS specimen is inclusion, and the fatigue initiates mainly at the surface and subsurface. While for the WAAM specimen, the most commonly found defects are pores, and the fatigue initiation is internal and at the subsurface. In addition, the fine microstructure, as well as the high strength and hardness, enable the WAAM material to have higher fatigue strength. In order to assess the effect of defects on fatigue performance, the stress intensity factor and El-Haddad model were adopted in the present study. It was found that the forged specimens with fish-eye (FIE) zones and the WAAM specimens with granular bright facet (GBF) zones have longer fatigue life. The fatigue strengths of the forged 13/4 MSS were therefore predicted by defect size. In contrast, the fatigue strengths of the WAAM 13/4 MSS were predicted by both defect and GBF sizes.