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<p>Metal wire fusion additive manufacturing (MWFAM), an emerging metal additive manufacturing technique, has the potential to mitigate some of the drawbacks of the powder bed fusion (PBF) and fused deposition modeling (FDM) processes. MWFAM offers some&#xa0;advantages, such as a higher deposition rate, larger build volume and nearly fully dense metal parts with minimal porosity. In the current study, MWFAM is performed on a mild steel substrate using an in-house developed experimental setup&#xa0;by&#xa0;modifying the&#xa0;metal inert gas (MIG) welding setup. Detailed experimentation has been conducted to develop predictive models to evaluate the correlation between the mechanical properties of the deposited parts and the input process parameters for metal deposition. Microscopic analysis of the deposited parts is performed to examine the grains in the deposited samples and typical defects, required&#xa0;to optimize the process further. The mechanical characterization of the deposited specimen reveals a maximum tensile strength of around 780&#xa0;MPa in the build direction. The maximum hardness of the deposited specimens is measured to be 35 HRD.</p>

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Experimental Analysis and Mechanical Characterization of Copper-Coated ER70S-6 Steel Wire Deposited on Mild Steel Substrate Using Metal Wire Fusion Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Sanjeev Kumar Verma,
  • Jitendra Singh,
  • Mahavir Singh,
  • Abhinav Verma,
  • Jitendra Bhaskar

摘要

Metal wire fusion additive manufacturing (MWFAM), an emerging metal additive manufacturing technique, has the potential to mitigate some of the drawbacks of the powder bed fusion (PBF) and fused deposition modeling (FDM) processes. MWFAM offers some advantages, such as a higher deposition rate, larger build volume and nearly fully dense metal parts with minimal porosity. In the current study, MWFAM is performed on a mild steel substrate using an in-house developed experimental setup by modifying the metal inert gas (MIG) welding setup. Detailed experimentation has been conducted to develop predictive models to evaluate the correlation between the mechanical properties of the deposited parts and the input process parameters for metal deposition. Microscopic analysis of the deposited parts is performed to examine the grains in the deposited samples and typical defects, required to optimize the process further. The mechanical characterization of the deposited specimen reveals a maximum tensile strength of around 780 MPa in the build direction. The maximum hardness of the deposited specimens is measured to be 35 HRD.