Effective Strategies for Electron Beam Additive Manufacturing of Graded Metal Interfaces between Stainless Steel and Vanadium

Abstract

This work examines the feasibility of joining two dissimilar metals, vanadium (V) and wrought Nitronic 40 stainless steel, through electron beam additive manufacturing (EBAM). Depositing V on Nitronic 40 led to mixed results with some builds exhibiting microcracking and other builds exhibiting severe cracking resulting in delamination. These build failures are thought to be caused by a large coefficient of thermal expansion (CTE) mismatch and solubility issues, demonstrating the challenges associated with this material combination. The large melting temperature discrepancy between Nitronic 40 and V was thought to exacerbate the issues with CTE mismatch and solubility. Four strategies could be employed by EBAM to mitigate the observed issues to successfully deposit V on Nitronic 40: (1) adjust wire feed speed, (2) use dual wire feeders, (3) use different wire feedstocks to control composition, and (4) create a transition layer known as buttering to accommodate CTE mismatch.