Investigation of the microstructure and mechanical performance of bimetal components fabricated using CMT-based wire arc additive manufacturing

Abstract

Traditionally, wear-resistant components are manufactured by cladding hard facing material on the base metal. This production process is typically complicated, expensive, and time-consuming. This study proposes a method of fabricating components with high wear resistance requirements utilizing cold metal transfer based wire and arc additive manufacturing with hard facing welding wire as the consumable material. Thin-walled and block components were manufactured by depositing a combination of a low alloy steel, ER80S-G, and a hard facing material, MF6–55GP. Microstructure characterization and mechanical properties (hardness, tensile and Block-on-Ring wear test) were performed. The results revealed that the ER80S-G/MF6–55GP bimetal components were able to be fused with no detectable defects near the border. As the deposited height was increased, the residual stress also increased; this internal residual stress combined with the external tensile load lead to a very low tensile strength of 447.79 ± 24.32 MPa of the ER80S-G/MF6-55GP/ER80S-G sandwich structure. The microstructures, constituent phases, and hardness distributions differ greatly among the layers due to their different thermal histories. The wear weight loss varies as the load condition changes for both the MF6-55G and Cr12MoV steels. Compared to Cr12MoV, MF6-55GP weld metal exhibits better wear resistance at higher loads in dry sliding wear tests.

Investigating Inconel 625: Mechanical and Microstructural Changes Under Wire-Arc Additive Manufacturing

“…The microstructure within the sphere of 308L SS was characterized by vertically developing austenite dendrites and residual ferrite inside the austenite, as demonstrated by the ndings. The study [22] suggested cold metal transfer-based WAAM using hard face welding wire as the consumable material to fabricate components with high wear resistance criteria.Components with thin walls and blocks were deposited from a mixture of low alloy steel ER80S-G and di cult-facing material MF6-55GP. The results showed that there were no observable faults close to the boundary of the ER80S-G/MF6-55GP bimetal components during the fusion process.…”

On the Influence of Linear Energy/Heat Input Coefficient on Hardness and Weld Bead Geometry in Chromium-Rich Stringer GMAW Coatings

“…Moreover, geometrical deviation of the final part consists of the sum of deviations of a singular stringer bead and the deviations of solidifying weld beads layered onto excessively heated base of previous layers [ 29 , 30 ]. This problem is partially solved by the application of Fronius Cold Metal Transfer technology, nevertheless that technology is patented, expensive and excludes other current sources [ 31 , 32 , 33 , 34 ]. Another approach is to introduce an additional cooling subsystem [ 35 ], yet that can result in unwanted changes in the microstructure [ 36 , 37 ], although Reisgen et al reported that they observed no negative effects [ 38 ].…”

Development of a New Cold Metal Transfer Arc Additive Die Manufacturing Process

“…In general, the contact interface layer between the aluminium alloy and dissimilar metals includes a continuous layer and discontinuous layer [29]. No defects are present near the boundary between the two metals [30]. erefore, this study developed a CMT arc additive die-casting manufacturing process to overcome the disadvantages of traditional arc additive manufacturing in deposition accuracy and structural organisation performance and achieved an additive structure that meets industrial manufacturing standards.…”