Abstract
AISI 4140 powder was directly deposited on AISI 4140 wrought substrate using laser engineered net shaping (LENS) to investigate the compatibility of a LENS-deposited part with the substrate. Tensile testing at room temperature was performed to evaluate the interface bond performance and fracture behavior of the test specimens. All the samples failed within the as-deposited zone, indicating that the interfacial bond is stronger than the interlayer bond inside the deposit. The fracture surfaces were analyzed using scanning electron microscopy (SEM) and energy disperse X-ray spectrometry (EDS). Results show that the tensile fracture failure of the as-deposited part is primarily affected by lack-of-fusion defects, carbide precipitation, and oxide particles inclusions, which causes premature failure of the deposit by deteriorating the mechanical properties and structural integrity.
Highlights
AISI 4140 is one of the representative medium carbon and low alloy steels and widely used for manufacturing of many industrial components, such as gears, shafts, and rotors, due to its good hardenability, strength, toughness, and wear resistance [1,2,3,4]
When the components made of this alloy steel are exposed to harsh operating conditions, such as surface rolling and sliding contact, during their service life, they are susceptible to serious surface damage, such as micropitting, abrasive wear, and corrosion, which could accelerate premature failure and shorten the life cycle of these critical and expensive components [5,6]
Its interfacial bond and fracture behaviors were evaluated by means of tensile test
Summary
AISI 4140 is one of the representative medium carbon and low alloy steels and widely used for manufacturing of many industrial components, such as gears, shafts, and rotors, due to its good hardenability, strength, toughness, and wear resistance [1,2,3,4]. When the components made of this alloy steel are exposed to harsh operating conditions, such as surface rolling and sliding contact, during their service life, they are susceptible to serious surface damage, such as micropitting, abrasive wear, and corrosion, which could accelerate premature failure and shorten the life cycle of these critical and expensive components [5,6]. Once the failure occurs, the damaged component is discarded and replaced, resulting in excessive material waste and loss of high value-added components [8,9]. It is imperative to repair and reconstruct the worn and damaged components in order to extend the life span and minimize waste of expensive materials, economic losses, downtime, and embodied energy, thereby increasing the industrial competitiveness [12,13]
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