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<p>Gas Tungsten Arc Welding (GTAW)-based Wire Arc Additive Manufacturing (WAAM) is a direct energy-based metal additive manufacturing process used for fabricating large components. Due to its economical operation and ability to fabricate products from various metals, GTAW-based WAAM has become a widely used process for near-net-shape production. One of the major challenges in manufacturing Inconel 718 components through WAAM is achieving deposited layers with the maximum possible bead height and width. Maximizing these dimensions enhances the economic viability of WAAM adoption. However, fabricating Inconel 718 using WAAM is particularly challenging due to its low thermal conductivity, which affects the deposition process. To address this challenge, the present study investigates the single-layer deposition of Inconel 718 using GTAW-based WAAM under different deposition parameters to determine the optimal process conditions for achieving the highest bead height and width. The single-layer deposition experiments are conducted at three levels of process parameters, including a wire feed rate ranging from 1200&#xa0;mm/min to 2400&#xa0;mm/min, a current between 100&#xa0;A and 140&#xa0;A, and a torch travel speed varying from 50&#xa0;mm/min to 100&#xa0;mm/min. An analysis of variance (ANOVA) identifies current as the most influential parameter in achieving the optimal bead height and width. Based on the identified optimum conditions, a 29&#xa0;mm-high wall of Inconel 718 has been successfully fabricated. The fabricated wall exhibited a decrease in tensile strength with increasing height. In addition, the ductility in the deposition direction has been found to be 65.06% higher than at the bottom of the normal to the deposition direction. Grain structure analysis revealed that the first layer has finer grains, while the grains coarsened with increasing height. A hardness analysis of the fabricated wall shows a decreasing trend at the top of the deposition by 4.55% compared to the bottom of the wall.</p>

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Analysis of microstructure and strength of Inconel 718 fabricated via optimal conditions of wire arc additive manufacturing process

  • 期刊论文

  • 发表日期：

    2025年7月7日

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  • Alok Kumar,
  • Suresh Kumar Reddy Narala,
  • Kundan Kumar Singh

摘要

Gas Tungsten Arc Welding (GTAW)-based Wire Arc Additive Manufacturing (WAAM) is a direct energy-based metal additive manufacturing process used for fabricating large components. Due to its economical operation and ability to fabricate products from various metals, GTAW-based WAAM has become a widely used process for near-net-shape production. One of the major challenges in manufacturing Inconel 718 components through WAAM is achieving deposited layers with the maximum possible bead height and width. Maximizing these dimensions enhances the economic viability of WAAM adoption. However, fabricating Inconel 718 using WAAM is particularly challenging due to its low thermal conductivity, which affects the deposition process. To address this challenge, the present study investigates the single-layer deposition of Inconel 718 using GTAW-based WAAM under different deposition parameters to determine the optimal process conditions for achieving the highest bead height and width. The single-layer deposition experiments are conducted at three levels of process parameters, including a wire feed rate ranging from 1200 mm/min to 2400 mm/min, a current between 100 A and 140 A, and a torch travel speed varying from 50 mm/min to 100 mm/min. An analysis of variance (ANOVA) identifies current as the most influential parameter in achieving the optimal bead height and width. Based on the identified optimum conditions, a 29 mm-high wall of Inconel 718 has been successfully fabricated. The fabricated wall exhibited a decrease in tensile strength with increasing height. In addition, the ductility in the deposition direction has been found to be 65.06% higher than at the bottom of the normal to the deposition direction. Grain structure analysis revealed that the first layer has finer grains, while the grains coarsened with increasing height. A hardness analysis of the fabricated wall shows a decreasing trend at the top of the deposition by 4.55% compared to the bottom of the wall.