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<p>This study investigates the fabrication of corrosion-resistant AISI SS347 stainless steel using an advanced double-pulse metal inert gas (MIG)–based Wire Arc Additive Manufacturing (WAAM) process. Owing to its excellent stability in aggressive chloride environments, SS347 was deposited in a layer-by-layer manner using a 1.2&#xa0;mm diameter wire under argon shielding to minimize oxidation. Wall structures measuring 250&#xa0;mm × 75&#xa0;mm × 12&#xa0;mm were fabricated, and key process parameters—current, voltage, wire feed rate, and travel speed—were optimized using the Taguchi design of experiments approach to ensure dimensional accuracy and structural integrity. The optimized conditions (179 A, 21.0&#xa0;V, 7&#xa0;mm/s) facilitated uniform material deposition with minimal defects, and test coupons were subsequently extracted by wire-cut electrical discharge machining (EDM) for further characterization. While, Wire Arc Additive Manufacturing (WAAM) is gaining momentum, its application to high-alloy austenitic stainless steels like SS347 remains underexplored. This work fills that gap by offering novel insights into the process–microstructure–corrosion relationship, positioning WAAM as a scalable, efficient solution for fabricating high-performance components for critical industrial applications. Electrochemical corrosion tests and Nano structural analysis using scanning electron microscope (SEM) revealed a stable microstructure and preserved elemental integrity in the WAAM-built sample, comparable to the base metal. Electrochemical testing revealed a progressive reduction in corrosion current density from 1.46 × 10<sup>−6</sup> A/cm<sup>2</sup> (bare substrate) to 0.25 × 10<sup>−6</sup> A/cm<sup>2</sup> (top layer), accompanied by a rise in polarization resistance from 18.2 kΩ to 46.7 kΩ. Correspondingly, the corrosion rate decreased from 0.0062 to 0.0013 mmpy, confirming that WAAM-fabricated SS347 exhibits corrosion resistance comparable to wrought alloys.</p>

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Designing Corrosion-Resilient SS347 Structures through Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年12月6日

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  • Selvam Vignesh,
  • Shanmugam Suresh Kumar,
  • Sundaresan Thirumalai Kumaran,
  • Roshan Kuruvila

摘要

This study investigates the fabrication of corrosion-resistant AISI SS347 stainless steel using an advanced double-pulse metal inert gas (MIG)–based Wire Arc Additive Manufacturing (WAAM) process. Owing to its excellent stability in aggressive chloride environments, SS347 was deposited in a layer-by-layer manner using a 1.2 mm diameter wire under argon shielding to minimize oxidation. Wall structures measuring 250 mm × 75 mm × 12 mm were fabricated, and key process parameters—current, voltage, wire feed rate, and travel speed—were optimized using the Taguchi design of experiments approach to ensure dimensional accuracy and structural integrity. The optimized conditions (179 A, 21.0 V, 7 mm/s) facilitated uniform material deposition with minimal defects, and test coupons were subsequently extracted by wire-cut electrical discharge machining (EDM) for further characterization. While, Wire Arc Additive Manufacturing (WAAM) is gaining momentum, its application to high-alloy austenitic stainless steels like SS347 remains underexplored. This work fills that gap by offering novel insights into the process–microstructure–corrosion relationship, positioning WAAM as a scalable, efficient solution for fabricating high-performance components for critical industrial applications. Electrochemical corrosion tests and Nano structural analysis using scanning electron microscope (SEM) revealed a stable microstructure and preserved elemental integrity in the WAAM-built sample, comparable to the base metal. Electrochemical testing revealed a progressive reduction in corrosion current density from 1.46 × 10−6 A/cm2 (bare substrate) to 0.25 × 10−6 A/cm2 (top layer), accompanied by a rise in polarization resistance from 18.2 kΩ to 46.7 kΩ. Correspondingly, the corrosion rate decreased from 0.0062 to 0.0013 mmpy, confirming that WAAM-fabricated SS347 exhibits corrosion resistance comparable to wrought alloys.