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<p>This study presents the fabrication and comprehensive characterization of a low carbon steel cylindrical component produced using cold metal transfer-based wire arc additive manufacturing. The fabricated structure exhibited excellent geometric accuracy with a maximum contour deviation below 1&#xa0;mm and was free from visible defects. Microstructural analysis revealed a uniform distribution of dendritic structures with both fine and coarse grains, indicating controlled thermal gradients. The component achieved a high tensile strength of 333.33 ± 2.2&#xa0;MPa and a tensile modulus of 93.75 ± 1.5&#xa0;GPa, with fractographic evidence of ductile failure. Consistent hardness of 218 ± 5&#xa0;HV and minimal thermal mass gain of 0.19% up to 1100&#xa0;°C reflected stable thermal and mechanical properties. Differential scanning calorimetry indicated a broad endothermic transformation near 700&#xa0;°C, and x-ray diffraction showed strong grain orientation perpendicular to the substrate. With a low surface roughness of Ra 0.046&#xa0;mm and hydrophilic behavior confirmed by contact angle analysis, the component demonstrates promising applicability in marine and structural applications. These findings highlight the viability of cold metal transfer-based wire arc additive manufacturing for producing dimensionally accurate and mechanically robust steel components.</p>

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Mechanical, Thermal, and Microstructure Characterization of ER90S-B3 on SS347 Substrate Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月7日

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  • S. Rashia Begum,
  • R. Samprashanth,
  • M. Vasumathi,
  • K. Vigneshwaran,
  • N. Venkateshwaran

摘要

This study presents the fabrication and comprehensive characterization of a low carbon steel cylindrical component produced using cold metal transfer-based wire arc additive manufacturing. The fabricated structure exhibited excellent geometric accuracy with a maximum contour deviation below 1 mm and was free from visible defects. Microstructural analysis revealed a uniform distribution of dendritic structures with both fine and coarse grains, indicating controlled thermal gradients. The component achieved a high tensile strength of 333.33 ± 2.2 MPa and a tensile modulus of 93.75 ± 1.5 GPa, with fractographic evidence of ductile failure. Consistent hardness of 218 ± 5 HV and minimal thermal mass gain of 0.19% up to 1100 °C reflected stable thermal and mechanical properties. Differential scanning calorimetry indicated a broad endothermic transformation near 700 °C, and x-ray diffraction showed strong grain orientation perpendicular to the substrate. With a low surface roughness of Ra 0.046 mm and hydrophilic behavior confirmed by contact angle analysis, the component demonstrates promising applicability in marine and structural applications. These findings highlight the viability of cold metal transfer-based wire arc additive manufacturing for producing dimensionally accurate and mechanically robust steel components.