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<p>Wire arc additive manufacturing (WAAM) using the cold metal transfer (CMT) process has emerged as a transformative method for producing near-net-shape metal components with tailored microstructures and enhanced mechanical performance. This study investigates the wear characteristics of components fabricated using CMT-based WAAM with ER70S-6 low-carbon steel (LCS) and 316LSi stainless steel (SS), focusing on their potential for abrasive and erosive wear applications. Microstructural analysis, including phase transformations and grain morphology, was performed in both the deposition (X) and building (Y) directions. Wear testing was conducted on a pin-on-disc machine under varying loads (1.5–3.5&#xa0;kg) and sliding speeds (150–450&#xa0;rpm) to evaluate wear rates, coefficients of friction (COF), and wear track morphology. The microstructure of the WAAMed LCS component is characterized by lamellar structures of ferrite and pearlite, with variations observed along the X- and Y-directions. The X-direction shows ferrite structures including polygonal ferrite and Widmanstätten ferrite (<i>α</i><sub>WD</sub>), while the Y-direction exhibits acicular ferrite (<i>α</i><sub>ac</sub>) and bainite (B) phases. The WAAMed 316LSi SS shows austenitic structures with residual ferrite, exhibiting lathy ferrite morphology in the X-direction and vermicular ferrite in the Y-direction. At the highest load and speed, the wear rate of 316LSi SS was reduced by 83.51% compared to LCS, with wear rates ranging from 0.74 × 10<sup>3</sup> to 1.98 × 10<sup>3</sup>&#xa0;g/m for 316LSi SS, and from 1.64 × 10<sup>4</sup> to 2.65 × 10<sup>4</sup>&#xa0;g/m for LCS. The COF for 316LSi SS remained within 0.34–0.45, significantly lower than the 0.53–0.57 observed for LCS. SEM analysis of worn surfaces identified abrasive, adhesive, and delamination wear as predominant mechanisms for LCS, whereas 316LSi SS showed minimal material loss due to its higher hardness (193–227&#xa0;HV<sub>0.5</sub> vs. 160–187&#xa0;HV<sub>0.5</sub> for LCS) and stable microstructure. These results establish WAAM-fabricated 316LSi SS as a promising material for wear-critical applications, providing a foundation for optimizing processing parameters and material properties.</p> Graphical Abstract <p></p>

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Wire Arc Additive Manufactured Low-Carbon Steel and Austenitic Stainless Steel Components: Microstructure and Wear Properties

  • 期刊论文

  • 发表日期：

    2025年5月30日

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  • Prasanna Nagasai Bellamkonda,
  • Maheshwar Dwivedy,
  • Lahari Gudapati,
  • Ramaswamy Addanki,
  • Nagavalli Vegesna

摘要

Wire arc additive manufacturing (WAAM) using the cold metal transfer (CMT) process has emerged as a transformative method for producing near-net-shape metal components with tailored microstructures and enhanced mechanical performance. This study investigates the wear characteristics of components fabricated using CMT-based WAAM with ER70S-6 low-carbon steel (LCS) and 316LSi stainless steel (SS), focusing on their potential for abrasive and erosive wear applications. Microstructural analysis, including phase transformations and grain morphology, was performed in both the deposition (X) and building (Y) directions. Wear testing was conducted on a pin-on-disc machine under varying loads (1.5–3.5 kg) and sliding speeds (150–450 rpm) to evaluate wear rates, coefficients of friction (COF), and wear track morphology. The microstructure of the WAAMed LCS component is characterized by lamellar structures of ferrite and pearlite, with variations observed along the X- and Y-directions. The X-direction shows ferrite structures including polygonal ferrite and Widmanstätten ferrite (αWD), while the Y-direction exhibits acicular ferrite (αac) and bainite (B) phases. The WAAMed 316LSi SS shows austenitic structures with residual ferrite, exhibiting lathy ferrite morphology in the X-direction and vermicular ferrite in the Y-direction. At the highest load and speed, the wear rate of 316LSi SS was reduced by 83.51% compared to LCS, with wear rates ranging from 0.74 × 103 to 1.98 × 103 g/m for 316LSi SS, and from 1.64 × 104 to 2.65 × 104 g/m for LCS. The COF for 316LSi SS remained within 0.34–0.45, significantly lower than the 0.53–0.57 observed for LCS. SEM analysis of worn surfaces identified abrasive, adhesive, and delamination wear as predominant mechanisms for LCS, whereas 316LSi SS showed minimal material loss due to its higher hardness (193–227 HV0.5 vs. 160–187 HV0.5 for LCS) and stable microstructure. These results establish WAAM-fabricated 316LSi SS as a promising material for wear-critical applications, providing a foundation for optimizing processing parameters and material properties.

Graphical Abstract