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<p>Wire + arc additive manufacturing (WAAM) of Inconel 718 using cold metal transfer (CMT) was investigated to stabilize single-bead deposition and control as-deposited wall quality. A Box–Behnken response surface design spanning current 170–210 A, wire feed 6–9&#xa0;m·min⁻1, and contact tip-to-work distance 15–25&#xa0;mm produced predictive models for bead width (BW), bead height (BH), and dilution that were verified on three confirmation builds. The models reproduced the measurements with low error BW MAPE 0.45%, BH MAPE 1.25%, and dilution MAPE 0.79% with typical confirmation values of BW 9.66–9.72&#xa0;mm, BH 2.64–2.72&#xa0;mm, and dilution 30.8–31.5%. Microstructural observations revealed a columnar-to-equiaxed transition from base to top of the wall, consistent with the imposed thermal gradient. Correspondingly, Vickers microhardness (HV0.5) exhibited a through-height stratification, increasing from 235 ± 1.5 HV (top) and 245 ± 2.36 HV (middle) to 280 ± 2.67 HV (bottom), with the final layer 256 ± 1.8 HV. These results demonstrate that, in the as-deposited condition, carefully selected CMT-WAAM parameters enable dense, directionally solidified IN718 with predictable geometry and microstructure-linked hardness gradients, providing a robust baseline for subsequent qualification and application-specific property development.</p>

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Process Optimization and Microstructural Analysis of Inconel 718 Walls Produced By Cold Metal Transfer Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年9月23日

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  • V. Santhosh,
  • A. Krishnaveni,
  • D. Jebakani,
  • S. Gobinath

摘要

Wire + arc additive manufacturing (WAAM) of Inconel 718 using cold metal transfer (CMT) was investigated to stabilize single-bead deposition and control as-deposited wall quality. A Box–Behnken response surface design spanning current 170–210 A, wire feed 6–9 m·min⁻1, and contact tip-to-work distance 15–25 mm produced predictive models for bead width (BW), bead height (BH), and dilution that were verified on three confirmation builds. The models reproduced the measurements with low error BW MAPE 0.45%, BH MAPE 1.25%, and dilution MAPE 0.79% with typical confirmation values of BW 9.66–9.72 mm, BH 2.64–2.72 mm, and dilution 30.8–31.5%. Microstructural observations revealed a columnar-to-equiaxed transition from base to top of the wall, consistent with the imposed thermal gradient. Correspondingly, Vickers microhardness (HV0.5) exhibited a through-height stratification, increasing from 235 ± 1.5 HV (top) and 245 ± 2.36 HV (middle) to 280 ± 2.67 HV (bottom), with the final layer 256 ± 1.8 HV. These results demonstrate that, in the as-deposited condition, carefully selected CMT-WAAM parameters enable dense, directionally solidified IN718 with predictable geometry and microstructure-linked hardness gradients, providing a robust baseline for subsequent qualification and application-specific property development.