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<p>The present study investigates the wear behavior of Wire Arc Additive Manufactured (WAAM) Ti-6Al-4V alloy under varying process and tribological conditions to address the limited understanding of how deposition parameters influence wear performance. WAAM samples were fabricated at three distinct heat input levels and tested using a Taguchi L9 orthogonal design, considering applied load (1–5&#xa0;kg), sliding speed (1–2&#xa0;m/s), and heat input (535.5–1147.5&#xa0;J/s) as key variables. Statistical analysis revealed that applied load was the dominant factor affecting weight loss, contributing ~ 75% of the total variation, followed by sliding speed (~20%) and heat input (~5%). Conversely, the coefficient of friction (COF) was primarily governed by sliding speed, accounting for ~ 75% of its variation. The lowest wear rate (49.78&#xa0;mg) and minimum COF (0.30) were achieved at low load, high speed, and high heat input, conditions that enhanced surface hardness (~421 HV) due to <i>α</i>′-martensitic microstructural refinement. SEM–EDS analysis confirmed the formation of a stable oxide-based tribolayer, which reduced metal-to-metal contact and friction. The study establishes clear process–structure–property correlations, demonstrating that optimizing WAAM parameters can significantly improve wear resistance and operational reliability of Ti-6Al-4V components for aerospace and high-performance applications.</p>

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Influence of Process Parameters on Wear Properties of Wire Arc Additive Manufactured Ti-6Al-4V Alloy

  • 期刊论文

  • 发表日期：

    2026年1月16日

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  • Hemant Kaundal,
  • Ratnesh Kumar Raj Singh,
  • Tarun Kumar Bera

摘要

The present study investigates the wear behavior of Wire Arc Additive Manufactured (WAAM) Ti-6Al-4V alloy under varying process and tribological conditions to address the limited understanding of how deposition parameters influence wear performance. WAAM samples were fabricated at three distinct heat input levels and tested using a Taguchi L9 orthogonal design, considering applied load (1–5 kg), sliding speed (1–2 m/s), and heat input (535.5–1147.5 J/s) as key variables. Statistical analysis revealed that applied load was the dominant factor affecting weight loss, contributing ~ 75% of the total variation, followed by sliding speed (~20%) and heat input (~5%). Conversely, the coefficient of friction (COF) was primarily governed by sliding speed, accounting for ~ 75% of its variation. The lowest wear rate (49.78 mg) and minimum COF (0.30) were achieved at low load, high speed, and high heat input, conditions that enhanced surface hardness (~421 HV) due to α′-martensitic microstructural refinement. SEM–EDS analysis confirmed the formation of a stable oxide-based tribolayer, which reduced metal-to-metal contact and friction. The study establishes clear process–structure–property correlations, demonstrating that optimizing WAAM parameters can significantly improve wear resistance and operational reliability of Ti-6Al-4V components for aerospace and high-performance applications.