Additive manufacturing of a high resistance steel by MIG/MAG

Abstract

Additive manufacturing (AM) is considered to be part of the 4th Industrial Revolution in digital era with advances in product design, materials, process engineering and simulation and data transfer software. Recent developments focus in the production of metallic components with more complex shapes, big sizes at reduced costs. Special highlight has been given to welding technologies where the electric arc is the heat source and the consumable wire, the material to deposit. High deposition rate, relatively low costs and accessibility are the main reasons for the interest in wire and arc additive manufacturing (WAAM). This study focused on using WAAM to produce simple shapes in high strength low alloy steel and characterize: the process, the geometrical features and the mechanical and structural properties of deposited material. The influence of the process parameters on the deposition characteristics was also studied. It was concluded that arc welding is a feasible technology to produce components by WAAM in the material under study without internal defects. Both mechanical and structural characterization confirmed the integrity of produced parts. A constant material deposition was achieved, with a deposition width of about 5 mm and a waviness around 110 m, which is very much below reported results for other metallic materials. Tensile strength was above the one specified for the wire and is consistent with hardness measured, ranging from 800 MPa to 1 GPa depending on the heat input. Deposition rates from 122.9 to 427.5 cm3/h were obtained.