Effect of plasma spray FeCrAly coating on microstructural and mechanical properties of Ni61Cr22Mo9Fe5 - ER2209 nickel based alloy fabricated using wire arc additive manufacturing process

Abstract

In this current research, the Ni61Cr22Mo9Fe5 (NiCr) - ER2209 (FeCr) wire was proposed to produce a nickel based alloy materials utilising the wire arc additive manufacturing (WAAM) process. Wire arc additive manufacturing (WAAM) and wire arc additive manufacturing coated (WAAM-C) samples of two different types were created. In order to improve the WAAM sample's mechanical strength and corrosion resistance, the outer surface layer was coated using the plasma spray FeCrAlY composite coating technique. The deposition of powder was kept as constant as 200 µm during plasma spray coating process. Microstructure analyses showed that the composite bonding sample had NiFe2O4, Single phase nickel ferrite (SPNF), Ni-Co ferrite, α-phase, and Spinel ferrite structures. The metallic functional phase (MFP) of Ni61Cr22Mo9Fe5 - ER2209 wire was shaped utilizing additive manufacturing process, whilst homogeneous structure and NiCr structure were established collateral bonding in the base materials. Texture results of WAAM-C sample showed As1 < 111 > , As2 < 200 >, As3 < 211 > and As4 < 222 > cub structure at the outer surface. The hardness values of outer surface layers of WAAM-C have been continuously increased by 4 % compared to the WAAM sample. The hardness values of WAAM-C and WAAM were seen as 180 HV and 166 HV, respectively. The WAAM-C showed the elongation of 3 % and yield strength of 600 MPa. Further, the fracture morphology revealed that both the samples did not show dimples, void, crack and hole. WAAM-C materials achieved higher corrosion resistance and good surface finish. Further, potential dynamic investigations were conducted on both WAAM and WAAM-C samples.