Meltpool characteristics, microstructure, and corrosion performance of laser-directed energy deposition cladded 316L SS/X70 steel for oilfield applications

Abstract

In oilfield pipeline transmission, complex geometries such as elbows, reducers, tees, and orifices face significant corrosion risks, especially in aggressive environments where multiphase turbulent flow and chloride ions cause sharp variations in hydrodynamic parameters. This study explores a laser cladding approach to mitigate internal corrosion in these complex geometries. The Laser-Directed Energy Deposition (L-DED) technique, known for its precision and efficiency, is employed to apply corrosion-resistant 316 L stainless steel (SS) over API X70 steel. Key parameters, including laser power and scan speed, were varied across nine combinations to evaluate their effects on melt pool characteristics, microstructure, and corrosion properties of the clads. Results showed that as laser energy increased (higher power and lower scan speed), melt pool dimensions and heat-affected zone (HAZ) thickness also increased, with clad thickness and HAZ ranging from 172 to 504 µm and 159–272 µm, respectively. Cellular and columnar sub-grain structures were present across all process combinations, with sub-grain size increasing at higher laser energy. A notable variation in chromium content was detected, with the clad produced at 500 W and 720 mm/min exhibiting superior pitting and corrosion resistance. This high-energy clad featured 16.3 % chromium and larger sub-grain sizes, facilitating stable passive film formation during corrosion. The optimized clad demonstrated approximately two orders better corrosion performance than the base X70 steel. © 2025