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Thermal and microstructural analysis of intersections manufactured by wire arc additive manufacturing (WAAM)

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Abstract

Wire arc additive manufacturing (WAAM) stands out in manufacturing metallic structures due to its great potential for application in industry for automated production of parts with large dimensions and considerable geometric complexity. Due to the wide presence of ribs and wall crossovers in several mechanical components, this work studied the thermal behavior of the low alloy steel wire AWS ER80S-G in a 10-mm-wide and 90-degree intersection, discovering its influence on the microstructure and hardness of the material compared to a flat wall. Thermal analysis showed that the cooling rate at the intersection is lower than that of a flat wall. However, the evaluation of the cooling curves in a CCT diagram of the steel, later confirmed by a metallographic analysis, indicated that the difference between these two regions was insignificant, as the microstructure was quite similar between them (76% ferrite, 20% pearlite, and 4% retained austenite). On the other hand, there was a significant difference among the layers in the same region, ranging from the morphology of acicular grains at the base and top to equiaxed grains in the intermediate region (ASTM grain size 9). This difference in microstructure was significant for the hardness of the material according to the deposited layer; however, there were few differences between the intersection and the flat wall. Therefore, there are no significant differences between these regions concerning the microstructure or cooling rate, with the variances observed in the hardness being more significant only among the layers deposited.

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Data Availability

Data sets generated during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

The authors would like to thank the support of CIT-SENAI for providing equipment and technical support for the entire manufacturing process, machining, and microscopy analysis. We also thank LRSS-UFMG for carrying out the hardness tests. The authors are also grateful for the supply of raw materials by Belgo Bekaert, as well as the support of all people and companies involved in the CDT-MADA project (Senai-MG, Belgo Bekaert Arames, ArcelorMittal, MRS Logística, and Delp Engenharia).

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Authors and Affiliations

  1. Department of Mechanical Engineering, School of Engineering, Federal University of Minas Gerais (UFMG), Belo Horizonte, MG, 31270-901, Brazil

    Bruno Maciel Sousa & Fagner Guilherme Ferreira Coelho

  2. Innovation and Technology Center, National Industrial Learning Service (SENAI), Belo Horizonte, MG, 31035-536, Brazil

    Fagner Guilherme Ferreira Coelho, Givan Martins Macedo Júnior, Hellen Cristine Prata de Oliveira & Nilo Nogueira da Silva

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  1. Bruno Maciel Sousa
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Correspondence to Bruno Maciel Sousa.

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Sousa, B.M., Coelho, F.G.F., Júnior, G.M.M. et al. Thermal and microstructural analysis of intersections manufactured by wire arc additive manufacturing (WAAM). Weld World (2024). https://doi.org/10.1007/s40194-024-01735-3

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