AccScience Publishing / MSAM / Volume 5 / Issue 3 / DOI: 10.36922/MSAM026280066
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ORIGINAL RESEARCH ARTICLE

Achieving a balanced duplex microstructure and corrosion resistance in UNS S32707 hyper-duplex stainless steel fabricated using GMAW-based wire arc additive manufacturing

Muppala Prardhan Yogya1 ,  Arivazhagan Natarajan1*
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1 School of Mechanical Engineering, Vellore Institute of Technology, Vellore, Tamil Nadu , India
MSAM 2026, 5(3), 026280066 https://doi.org/10.36922/MSAM026280066
Received: 8 July 2026 | Revised: 11 August 2026 | Accepted: 17 August 2026 | Published online: 17 September 2026
© 2026 by the Author(s). This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

UNS S32707 Hyper-duplex stainless steels (HDSS) offer an attractive combination of high strength and corrosion resistance for demanding marine and offshore applications. A UNS S32707 HDSS wall was fabricated using gas metal arc welding (GMAW) combined with wire arc additive manufacturing (WAAM) for the subsea umbilical in marine engineering applications. The aim is to achieve a 50:50 ratio of austenite and ferrite phases and to suppress the formation of secondary phases; the balanced phase ratio provides a combination of mechanical properties and corrosion resistance. Microstructure evolution, mechanical behavior, and corrosion resistance of as-deposited UNS S32707 HDSS were comprehensively investigated. The electron backscatter diffraction analysis depicted a balanced duplex structure consisting of 52.1% ferrite, 47.4% austenite, and 0.5% sigma (σ) phase at the grain boundaries. The microstructure exhibited ferrite, intragranular austenite, Widmanstätten austenite, and grain-boundary austenite. Secondary phases, such as Cr2N, secondary austenite (γ2), and the chi (χ) phase, were not observed due to lower heat input and suitable inter-pass temperature. The tensile tests in three orientations (0°, 45°, 90°) relative to the build direction showed ultimate tensile strengths ranging from 927 MPa to 943 MPa, with elongations of 44% and an average hardness of 334 HV0.5. Fractographic analysis revealed ductile failure, exhibiting finer and more uniform dimples. The corrosion studies conducted using a potentiodynamic polarization test in a 3.5 wt.% NaCl solution showed good corrosion resistance, with a low corrosion rate of 0.07877 mm/year. These findings establish controlled GMAW-based WAAM as a promising route for producing phase-balanced UNS S32707 HDSS for demanding marine applications.

Graphical abstract
Keywords
Hyper-duplex stainless steel (HDSS)
Wire arc additive manufacturing
Gas metal arc welding
Electron backscatter diffraction analysis
Electrochemical corrosion behavior
Funding
The authors declare that no specific funding was received for this work.
Conflict of interest
The authors declare no conflict of interest.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing
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