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<p>This study investigates the effect of incorporating an SS 304 micro-interlayer (SS304-IL) in low alloy steel (ER70S6) fabricated using Cold Metal Transfer (CMT)-based Wire Arc Additive Manufacturing (WAAM) to enhance mechanical properties, microstructure, and corrosion resistance. Multi-layered samples were produced by manually introducing a 30&#xa0;µm-thick SS 304 thin film between successive ER70S6 layers, allowing the molten deposit to fuse the interlayer with the base material. Microstructural analysis revealed improved grain structure uniformity, with a slight increase in grain size from 8.52&#xa0;µm (ER70S6) to 9.21&#xa0;µm (SS304-IL) and an increase in ferrite content from 80.11 to 81.74%. The density of the interlayered sample increased to 7700&#xa0;kg/m<sup>3</sup>, while porosity was reduced from 1.84% to 1.55%, enhancing material integrity. Tensile testing in different orientations showed a reduction in anisotropy from 12.41% (ER70S6) to 3.54% (SS304-IL), indicating improved structural reliability. Hardness exhibited a slight increase from 177 HV to 180 HV. Corrosion resistance was assessed using electrochemical impedance spectroscopy (EIS), revealing a higher corrosion potential (Ecorr) of − 0.662&#xa0;V and a lower corrosion current density (Icorr) of − 6.3006 A/cm<sup>2</sup> in SS304-IL, compared to − 0.66562&#xa0;V and − 6.1283 A/cm<sup>2</sup> in ER70S6, respectively. These findings demonstrate that the SS 304 interlayer improves mechanical properties, reduces anisotropy, and enhances corrosion resistance, making it a promising approach for optimizing WAAM-fabricated components.</p>

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SS304 Micro-interlayered Low Alloy Steel Prepared via Cold Metal Transfer Based Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年4月25日

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  • Vivek Babu,
  • S. Krishnanunni,
  • Jinu Paul

摘要

This study investigates the effect of incorporating an SS 304 micro-interlayer (SS304-IL) in low alloy steel (ER70S6) fabricated using Cold Metal Transfer (CMT)-based Wire Arc Additive Manufacturing (WAAM) to enhance mechanical properties, microstructure, and corrosion resistance. Multi-layered samples were produced by manually introducing a 30 µm-thick SS 304 thin film between successive ER70S6 layers, allowing the molten deposit to fuse the interlayer with the base material. Microstructural analysis revealed improved grain structure uniformity, with a slight increase in grain size from 8.52 µm (ER70S6) to 9.21 µm (SS304-IL) and an increase in ferrite content from 80.11 to 81.74%. The density of the interlayered sample increased to 7700 kg/m3, while porosity was reduced from 1.84% to 1.55%, enhancing material integrity. Tensile testing in different orientations showed a reduction in anisotropy from 12.41% (ER70S6) to 3.54% (SS304-IL), indicating improved structural reliability. Hardness exhibited a slight increase from 177 HV to 180 HV. Corrosion resistance was assessed using electrochemical impedance spectroscopy (EIS), revealing a higher corrosion potential (Ecorr) of − 0.662 V and a lower corrosion current density (Icorr) of − 6.3006 A/cm2 in SS304-IL, compared to − 0.66562 V and − 6.1283 A/cm2 in ER70S6, respectively. These findings demonstrate that the SS 304 interlayer improves mechanical properties, reduces anisotropy, and enhances corrosion resistance, making it a promising approach for optimizing WAAM-fabricated components.