Abstract
This study aims at evaluating the effect of microstructure imperfections on the corrosion fatigue performance of an ER70S-6 alloy produced by wire arc additive manufacturing (WAAM) process, in a 3.5% NaCl solution. For reference, a regular ST-37 alloy with relatively similar chemical composition was considered as a counterpart alloy. This was justified by the fact that the ER70S-6 alloy is usually used for conventional welding of ST-37 steel. The results obtained indicated that while the ST-37 alloy exhibited fatigue strength of 240 MPa in the corrosive solution, the additively manufactured ER70S-6 alloy showed fatigue strength of only 140 MPa. These differences were related to microstructural imperfections that are inherently produced during the WAAM process.
Highlights
Additive manufacturing (AM), processes are principally divided into three main categories: powder-bed technology (PBT), inkjet printing and blown powder/wire technology
The wire arc additive manufacturing (WAAM) process is carried out using an electric arc as the energy source and consumable wires as the filler material for layer-by-layer metal deposition controlled by 3D CAD software, under an inert gas atmosphere [6,7]
The deposition rate of the raw material in the WAAM process is about 160 g/min [16], which is significantly higher than the 10 g/min obtained by conventional PBT
Summary
Additive manufacturing (AM), processes are principally divided into three main categories: powder-bed technology (PBT), inkjet printing and blown powder/wire technology. The wire arc additive manufacturing (WAAM) process is carried out using an electric arc as the energy source and consumable wires as the filler material for layer-by-layer metal deposition controlled by 3D CAD software, under an inert gas atmosphere [6,7]. Compared to powder-bed technologies, the WAAM process is significantly more attractive and cost-effective. This is manifested in terms of energy consumption (90% less than PBT), production cost, including raw materials, (80% less than PBT) and component dimensions that are not limited to the printing cell size [8,9,10,11,12,13,14,15]. The main disadvantage of WAAM technology compared to PBT relates to its inherent limitation in terms of possible geometrical structures that can be produced. The WAAM process can be used to produce bulk or hollow geometries that enable the deposition-tool-free access to the deposition area [18]
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