Wire arc direct energy deposited multiphase steel through in situ micropowder alloying: mechanical and metallurgical studies
Abstract
Purpose
This study aims to investigate the effect of copper and titanium micropowder addition on the mechanical and metallurgical properties of additively manufactured low-carbon steel, aiming to produce a modified (multiphase) steel with ferritic low-carbon steel using in situ micropowder addition during wire arc direct energy deposition (WA-DED).
Design/methodology/approach
A robotic arm equipped with a GMA welding source deposited ER70S6 filler wire on AISI S235 substrate steel using WA-DED. Cu and Ti micropowders were interspersed between layers for microstructural modifications. Microscopy, spectroscopy, diffraction and mechanical testing were used to evaluate the properties of the deposited samples.
Findings
Incorporating Cu and Ti micropowders significantly enhanced the yield and tensile strength of the deposited material, showing an 83% increase in yield strength and a 33% increase in tensile strength. Microstructural analysis identified key phases such as ferrite, pearlite, bainite, retained austenite and martensite/austenite, with Cu and Ti acting as grain refiners. Nanoscaled Cu precipitates contribute to enhanced low-temperature toughness and a 150% improvement in impact strength at −30°C.
Originality/value
This study presents a novel approach to overcome the limitations of the available alloys (filler materials). This can be achieved by introducing in situ micropowder alloying during the WA-DED process. The micropowder addition allows altering the properties of the deposited material without changing the parent filler material itself, achieving the desired composition. With this approach, there is no need to manufacture the filler material with the preferred alloy composition separately and then carry out the deposition process.
Keywords
Acknowledgements
The support of the School of Mechanical Sciences and Centre of Excellence in Particulates, Colloids and Interfaces at the Indian Institute of Technology Goa for WA-DED depositions, mechanical as well as metallurgical characterizations are gratefully acknowledged. The authors would especially like to thank Prof. Bidhan Paramanick for his constant and selfless support during SEM, EDS and XRD analyses of the samples. The authors are also thankful to Shri Parmeshwar M and Shri Diptesh R. Naik for their help during the fabrication of powder-feeding apparatus.
Data availability: The raw/processed data required to reproduce these findings are mentioned in the article.
Conflict of interest: On behalf of all the authors of this research article, the corresponding author states that there is no conflict of interest.
Funding: Indian Institute of Technology Goa funded this whole research expense.
Declaration of generative AI in scientific writing: No AI is used for scientific and technical writing.
Code availability: Not applicable.
Author's contributions: All authors of this paper have read and approved the final version submitted.
Ethics approval: Not applicable.
Consent to participate: Not applicable.
Consent for publication: All the authors agreed to publish this paper.
Citation
Prakash, A. and Kore, S.D. (2024), "Wire arc direct energy deposited multiphase steel through
Publisher
:Emerald Publishing Limited
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