A study on wire and arc additive manufacturing of low-carbon steel components: process stability, microstructural and me

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(2020) 42:480

TECHNICAL PAPER

A study on wire and arc additive manufacturing of low‑carbon steel components: process stability, microstructural and mechanical properties Van Thao Le1,2   · Dinh Si Mai2 · Quang Huy Hoang2 Received: 28 April 2020 / Accepted: 13 August 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020

Abstract Among metal-based additive manufacturing, wire and arc additive manufacturing is receiving increasing attention for the production of components with medium to large dimensions. In the current research, the production of low-carbon steel thin-walled components by wire and arc additive manufacturing was addressed. Firstly, the influence of two depositing direction strategies on the wall shape was investigated. Subsequently, the effect of heat input on the shape stability and the microstructure evolution of the walls was studied. The results indicated that the alternating depositing direction strategy was more suited to build thin walls with relatively regular height. The heat input significantly influenced the shape stability, but had slight effects on the microstructure evolution. The microstructure of the walls varied from the top to the bottom regions, leading to a variation in hardness from 157 ± 3.11 to 192 ± 4.30 (HV5). The microstructure of the built thin walls can be distinguished in three regions: The upper region exhibited lamellar structures; the middle region dominantly featured granular structures of ferrites with a small proportion of pearlites, which appear in the boundaries of grains; and the lower region showed a mix of lamellar and equiaxed structures of ferrites. The tensile properties of the built material also exhibited anisotropic characteristics: The yield strength and ultimate tensile strength vary from 320 ± 6 to 362 ± 8 MPa and from 429 ± 8 to 479 ± 7 MPa, respectively. Keywords  Wire and arc additive manufacturing · Low-carbon steel · Microstructure · Mechanical properties

1 Introduction In the last decades, additive manufacturing (AM) has emerged as a new technology for manufacturing parts with highly complex geometries, including internal structures. The AM technique allows the manufacture of a physical part directly from its CAD model without requiring extra resources, for example cutting tools, jigs, and coolant fluids as in machining [1]. Thanks to the layer-by-layer manufacturing principle, AM uses only an amount of materials required to build designed parts and support structures if Technical Editor: Lincoln Cardoso Brandao. * Van Thao Le [email protected] 1



Institute of Research and Development, Duy Tan University, Da Nang 550000, Vietnam



Advanced Technology Center, Le Quy Don Technical University, Hanoi 100000, Vietnam

2

necessary. Thus, the waste of materials and environmental impacts could be reduced [2, 3]. AM also enables the topological optimization for saving raw materials [4]. Nowadays, AM technologies, in particular metallic AM technologies, are effectively used in aeronautics, automobile, and biomedical engineering