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<p>Wire arc additive manufacturing (WAAM) is a metal 3D printing process that builds parts layer by layer using a wire feed and an electric arc as the heat source. This study examines the microstructure and mechanical properties of fabricated components using AISI 4340 filler wire via GTAW -based WAAM process. Microstructural analysis using FESEM and EBSD revealed minor variations between the first, middle, and last built regions. The last build region exhibited finer polygonal ferrite phase with secondary phase particles due to rapid cooling and limited reheating. The first build region shows coarser grains comprising of polygonal ferrite phase and pearlite phase due to first build was attributed to multiple thermal cycles and slower cooling rates. EBSD analysis further indicated a reduced density of high-angle grain boundaries in the first build region, linked to insufficient dynamic recrystallization. Mechanical testing indicated minor variations in tensile properties along the build direction compared to across it, with both orientations showing ductile fracture behavior characterized by dimples. The presence of the Portevin–Le Chatelier effect was observed along (middle) and across build direction and linked to dynamic strain aging. The ratio of wire feed speed to travel speed was found to significantly influence bead geometry.</p>

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Microstructure Characterization and Mechanical Behavior of 3D-Fabricated Part via Gas Tungsten Arc Welding-Based Wire Arc Additive Manufacturing Process Using AISI4340 Wire

  • 期刊论文

  • 发表日期：

    2025年8月18日

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  • Jai Prakash Kamal,
  • Gaurav Sharma,
  • Akurathi Yogesh,
  • Rahul S. Mulik,
  • Abinash Kumar Swain

摘要

Wire arc additive manufacturing (WAAM) is a metal 3D printing process that builds parts layer by layer using a wire feed and an electric arc as the heat source. This study examines the microstructure and mechanical properties of fabricated components using AISI 4340 filler wire via GTAW -based WAAM process. Microstructural analysis using FESEM and EBSD revealed minor variations between the first, middle, and last built regions. The last build region exhibited finer polygonal ferrite phase with secondary phase particles due to rapid cooling and limited reheating. The first build region shows coarser grains comprising of polygonal ferrite phase and pearlite phase due to first build was attributed to multiple thermal cycles and slower cooling rates. EBSD analysis further indicated a reduced density of high-angle grain boundaries in the first build region, linked to insufficient dynamic recrystallization. Mechanical testing indicated minor variations in tensile properties along the build direction compared to across it, with both orientations showing ductile fracture behavior characterized by dimples. The presence of the Portevin–Le Chatelier effect was observed along (middle) and across build direction and linked to dynamic strain aging. The ratio of wire feed speed to travel speed was found to significantly influence bead geometry.