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<p>This study investigates the effects of interlayer hammering on Rotational Arc-based wire arc additive manufacturing (RA-WAAM) samples, focusing on mechanical, microstructural, wear and corrosive properties. The RA-WAAM process combined with interlayer hammering achieved an average tensile strength of&#xa0;670 MPa&#xa0;and&#xa0;13% elongation, outperforming non-hammered specimens from traditional welding techniques by almost 210MPa and conventional RA-WAAM by 120MPa. Microstructural analysis revealed a refined average grain size of&#xa0;14 µm, comprising polygonal/acicular ferrite with traces of pearlite and retained austenite. The interlayer hammering induced grain refinement through mechanical deformation, elevating dislocation density and enhancing mechanical strength and hardness (170 HV<sub>0.5</sub>). Wear studies showed that the build displayed a Lancaster wear coefficient of&#xa0;0.0000195 mm<sup>3</sup>/Nm. These enhancements were stemmed from grain refinement and strain hardening without compositional changes. However, the build displayed a corrosion rate of&#xa0;0.112 mm/year&#xa0;which exceeded the values for the conventional WAAM techniques, which could be attributed to increased grain boundary density from refinement, which accelerated electrochemical activity in the absence of passivating elements. These findings highlight interlayer hammering as an effective strategy for enhancing RA-WAAM mechanical performance through microstructural optimization, though corrosion resistance requires further improvement for broader applications.</p> Graphical Abstract <p></p>

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Synergistic Effects of Arc Rotation and Interlayer Hammering on ER70S6 Components Fabricated with Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • C. T. Justus Panicker,
  • V. Senthilkumar

摘要

This study investigates the effects of interlayer hammering on Rotational Arc-based wire arc additive manufacturing (RA-WAAM) samples, focusing on mechanical, microstructural, wear and corrosive properties. The RA-WAAM process combined with interlayer hammering achieved an average tensile strength of 670 MPa and 13% elongation, outperforming non-hammered specimens from traditional welding techniques by almost 210MPa and conventional RA-WAAM by 120MPa. Microstructural analysis revealed a refined average grain size of 14 µm, comprising polygonal/acicular ferrite with traces of pearlite and retained austenite. The interlayer hammering induced grain refinement through mechanical deformation, elevating dislocation density and enhancing mechanical strength and hardness (170 HV0.5). Wear studies showed that the build displayed a Lancaster wear coefficient of 0.0000195 mm3/Nm. These enhancements were stemmed from grain refinement and strain hardening without compositional changes. However, the build displayed a corrosion rate of 0.112 mm/year which exceeded the values for the conventional WAAM techniques, which could be attributed to increased grain boundary density from refinement, which accelerated electrochemical activity in the absence of passivating elements. These findings highlight interlayer hammering as an effective strategy for enhancing RA-WAAM mechanical performance through microstructural optimization, though corrosion resistance requires further improvement for broader applications.

Graphical Abstract