High-Temperature Wear Properties of Laser Powder-Directed Energy Deposited Ferritic Stainless Steel 430

Ferritic stainless steels (FSSs) have attracted considerable attention due to their excellent corrosion resistance and significantly lower cost compared to nikel-bearing austenitic stainless steels. However, the high-temperature wear behavior of additively manufactured FSS 430 has not yet been thoroughly investigated. This study aims to examine the microstructural characteristics and wear properties of laser powder-directed energy deposition (LP-DED) FSS 430 fabricated under varying laser powers and hatch distances. Wear testing was conducted at 25 °C and 300 °C after subjecting the samples to solution heat treating at 815 °C and 980 °C for 1 hour, followed by forced fan cooling. For comparison, an AISI 430 commercial plate was also tested under the same test conditions. Microstructural evolution and worn surfaces were analyzed using SEM-EDS and EBSD techniques. Wear performance was evaluated based on friction coefficients and cross-sectional profiles of wear tracks, including wear volume, maximum depth, and scar width. The average friction coefficients (AFCs) of samples solution heat treated at 980 °C were higher than those treated at 815 °C. Additionally, AFCs increased with hatch distance at both testing temperatures. A strong correlation was observed between Rockwell hardness and wear resistance, indicating that higher hardness generally results in improved wear performance.