R. E. Alekseev Nizhny Novgorod State Technical University (Nizhny Novgorod, Russia)

M. S. Anosov, Cand. Eng., Associate Prof., Dept. of Mechanical Engineering Technology and Equipment
D. A. Ryabov, Cand. Eng., Associate Prof., Dept. of Materials Science, Materials Technology and Metal Heat Treatment, riabov.da@nntu.ru

Wire Arc Additive Manufacturing (WAAM) is promising for the production of large-sized products, but its implementation is hindered by anisotropy of properties, the growth of large columnar grains and residual stresses. These problems are particularly acute for steel 09Mn2Si (shipbuilding, pipelines) and steel AISI 316L (chemical and oil and gas engineering). Dispersed powder alloying (the introduction of micron (up to 50 μm) metal particles into welding) allows you to control the structure and properties of metals and alloys. The aim of the work is to establish the patterns of influence of the type of highly dispersed alloying powder (nickel PNK–UT3, copper PMS-1, aluminum PAP-1 and nitinol (Ni-Ti)) during WAAM printing on the chemical composition, microstructure and its fractal dimension, as well as the hardness of steels 09Mn2Si and AISI 316L. Using the developed automated powder supply module, the stability of arc gorenje, microstructure, hardness and fractal dimension of the resulting metal were studied. It is shown that the stability of the WAAM process is determined by the powder consumption (the optimal consumption is 4 g/s), and the layer-by-layer feeding through the developed device ensures a uniform distribution of alloying elements. It was found that for steel 09Mn2Si, highly dispersed nickel alloying contributes to the formation of a needle-like bainite structure with an increase in hardness by 30.1 %. The maximum increase in hardness (by 32.7 %) was recorded when using copper powder (PMS-1). For austenitic AISI 316L steel, alloying practically does not change the hardness due to the complete dissolution of the elements in the crystal lattice of austenite, however, it leads to grinding and a change in the morphology of the dendritic structure. For AISI 316L steel, the critical limitation is the formation of hot cracks when alloyed with copper (PMS-1 powder).

This work was supported by the Russian Science Foundation (RSF) grant No. 25-19-00534, “Development of scientific principles regarding the fatigue failure of layer-by-layer modified composite materials obtained by additive arc surfacing.”

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