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<p>Wire Arc Additive Manufacturing (WAAM) is a cost-effective method for fabricating large structural components from Inconel 718 (IN718), a nickel-based superalloy. However, this process encounters challenges such as residual stresses and undesirable microstructures, which can lead to dimensional instability and poor mechanical performance. To mitigate these issues, in this study, an in-situ hammering (IsH) approach was applied during the WAAM fabrication of IN718 wall structures to modify microstructural evolution and enhance hardness characteristics. The effects of the IsH sample were systematically compared with the as-deposited (AD) component along both the build direction (BD) and deposition direction (DD). The results demonstrate that IsH significantly refined grain size and reduced dislocation density and microstrain in the BD by 40.2%, 53.03%, and 16.11%, respectively, and in the DD by 26.44%, 16.11%, and 19.05%, respectively, compared to the AD samples. Additionally, the IsH process increased the average crystallite size and hardness value by 38.16% and 12.19% in the BD, and by 18.75% and 13.53% in the DD, compared to the AD sample. Texture analysis indicated that IsH inhibits the strong, directionally biased textures usually created during WAAM process and instead encourages more stable and less anisotropic crystallographic orientations. In conclusion, the integration of IsH during the WAAM process provides a practical advantage compared to the traditional WAAM process by reducing microstructural anisotropy and enhancing hardness uniformity without requiring additional post-processing, making it particularly appealing for producing large IN718 parts.</p>

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Enhancing microstructure and hardness of WAAM-fabricated inconel 718 through in-situ hammering

  • 期刊论文

  • 发表日期：

    2026年2月25日

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  • Mriganka Maity,
  • Manivannan Raja,
  • Manidipto Mukherjee

摘要

Wire Arc Additive Manufacturing (WAAM) is a cost-effective method for fabricating large structural components from Inconel 718 (IN718), a nickel-based superalloy. However, this process encounters challenges such as residual stresses and undesirable microstructures, which can lead to dimensional instability and poor mechanical performance. To mitigate these issues, in this study, an in-situ hammering (IsH) approach was applied during the WAAM fabrication of IN718 wall structures to modify microstructural evolution and enhance hardness characteristics. The effects of the IsH sample were systematically compared with the as-deposited (AD) component along both the build direction (BD) and deposition direction (DD). The results demonstrate that IsH significantly refined grain size and reduced dislocation density and microstrain in the BD by 40.2%, 53.03%, and 16.11%, respectively, and in the DD by 26.44%, 16.11%, and 19.05%, respectively, compared to the AD samples. Additionally, the IsH process increased the average crystallite size and hardness value by 38.16% and 12.19% in the BD, and by 18.75% and 13.53% in the DD, compared to the AD sample. Texture analysis indicated that IsH inhibits the strong, directionally biased textures usually created during WAAM process and instead encourages more stable and less anisotropic crystallographic orientations. In conclusion, the integration of IsH during the WAAM process provides a practical advantage compared to the traditional WAAM process by reducing microstructural anisotropy and enhancing hardness uniformity without requiring additional post-processing, making it particularly appealing for producing large IN718 parts.