Abstract

Hydrogen reduction of metal oxides offers a promising pathway toward carbon and energy efficient steel production, but the high cost of hydrogen and the complexity of conventional processing routes present challenges to widespread implementation. One potential approach is the development of extrusion-based near-net-shape manufacturing, in which metal oxide precursors are shaped into components prior to hydrogen reduction and sintering. This approach also enables the fabrication of bimetallic structures, combining dissimilar steel compositions to achieve properties that cannot be obtained from a single material. However, differences in reduction kinetics, sintering shrinkage, and thermal expansion between constituent materials can generate differential strains, residual stresses, and interfacial defects that compromise structural integrity. In this work, the fabrication of stainless steel 316/carbon steel bimetallic components through hydrogen reduction and sintering of extruded oxide mixtures is investigated.