Finite element analysis driven study on SS316 cladding of mild steel for enhanced durability in agricultural tools

The study focuses on enhancing the wear resistance of mild steel used in agricultural tools by cladding it with SS316 stainless steel using Wire Arc Additive Manufacturing (WAAM) integrated with Cold Metal Transfer (CMT). Finite Element Analysis (FEA) was employed to optimize the process parameters, ensuring uniform temperature distribution and minimal thermal stresses during cladding. To simulate field conditions, the cladded samples were subjected to rigorous dry abrasion tests under varying loads, particle sizes, and sand flow rates. The results revealed that the SS316 cladding exhibited up to 50% lower mass loss than mild steel, reflecting a significant improvement in wear resistance. This enhanced performance is attributed to the superior microhardness of SS316 (325 ± 3 HV_4.9 N) compared to mild steel (152 ± 2 HV_4.9 N). Microstructural analysis revealed that rapid cooling during deposition led to a refined grain structure, enhancing the mechanical strength of the clad. SEM analysis of worn surfaces further elucidated the wear mechanisms, highlighting the cladding’s ability to resist abrasive penetration and minimize mass loss. The study concludes that SS316 cladding on mild steel is a viable solution for extending the service life of agricultural tools, reducing maintenance costs, and improving operational efficiency. These findings contribute to the development of more durable materials for agricultural and industrial applications exposed to abrasive conditions.