Mechanical behaviors and wear resistances of 3D-printed AISI 321 components for combustor swirler applications

This comprehensive study investigates the mechanical behaviors and wear characteristics of 3D-printed AISI 321, with a specific focus on its applicability in combustion swirler components for the power generation industry. Through meticulous exploration of various process parameters and postprocessing techniques, valuable insights were gained into the performance disparities between layered and cast specimens. Analyses revealed intriguing comparisons of key data points: while layered specimens exhibited higher surface roughness (4.37 mu m), they demonstrated a lower friction coefficient (0.26) yet a higher wear rate (4.79 x 10-7 mm3/N center dot mm) compared to their cast specimens. Further investigation into the influence of layering direction unveiled that horizontally layered specimens presented smoother surfaces (0.26 mu m), higher hardness (340 HV 1), and improved wear resistance (2.61 x 10-7 mm3/N center dot mm) compared to vertically layered specimens. Furthermore, the study examined the friction and wear characteristics of layered specimens based on the contact surface, including the top, side, and bottom surfaces. Lastly, a comparison of the mechanical behavior and friction/wear characteristics of layered specimens and cast specimens was conducted, demonstrating that the layered specimens fabricated using the Laser Powder Bed Fusion (LPBF) method exhibited superior performance. These findings underscore the significant potential of 3D-printed AISI 321 in enhancing performance and sustainability in power generation applications, while highlighting the ongoing need for continued research and development to fully exploit the capabilities of additive manufacturing technologies.