Additive manufacturing (AM) is a relatively new manufacturing method that can produce complex geometries and optimized shapes with less process steps. In addition to distinct microstructural features, residual stresses and their formation are also inherent to AM components. AM components require several post-processing steps before they are ready for use. To change the traditional manufacturing method to AM, comprehensive characterization is needed to verify the suitability of AM components. On very demanding corrosion atmospheres, the question is does AM lower or eliminate the risk of stress corrosion cracking (SCC) compared to welded 316L components? This work concentrates on post-processing and its influence on the microstructure and surface and subsurface residual stresses. The shot peening (SP) post-processing levelled out the residual stress differences, producing compressive residual stresses of more than −400 MPa in the AM samples and the effect exceeded an over 100 µm layer below the surface. Post-processing caused grain refinement and low-angle boundary formation on the sample surface layer and silicon carbide (SiC) residue adhesion, which should be taken into account when using the components. Immersion tests with four-point-bending in the heated 80 °C magnesium chloride solution for SCC showed no difference between AM and reference samples even after a 674 h immersion.

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Thick wear-resistant steel plates are utilized in challenging applications, which require a high hardness and toughness. However, utilization of the thick plates is problematic as they often have nonuniform mechanical properties along the thickness direction due to the manufacturing-induced segregations. In addition, the processing of thick plates commonly involves flame cutting, which causes several challenges. Flame cutting forms a heat-affected zone and generates high residual stresses during the cutting process. In the worst case, flame cutting causes cracking of the cut edge. The aim of this study is to investigate the role of plate thickness on the residual stress formation and cracking behavior when utilizing flame cutting. Residual stress profiles are measured by X-ray diffraction, plates and cut edges and are mechanically tested and characterized by electron microscopy. The results show that thicker plates generate more unfavorable residual stress state during flame cutting. Thick plates also contain segregations, which have decreased mechanical properties. The combination of high residual tensile stresses and segregations increase the risk of cracking during flame cutting. To prevent the cracking, the residual stresses should be lowered by lower cutting speeds and preheating. In addition, manufacturing practices should be aimed at lowering segregation formation in thick plates.

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