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<p>This study presents a comprehensive investigation into the microstructural evolution and mechanical performance of an Inconel 617 wall fabricated using the wire arc additive manufacturing (WAAM) process. Detailed microstructural characterization reveals a gradient in grain morphology along the build direction, driven by variations in thermal history. Equiaxed dendrites and columnar grains due to rapid solidification were noticed near the substrate and are mixed together in the bottom layers, while cellular structures and columnar dendrites are dominant in the middle layers. Columnar and elongated columnar dendrites were observed in the upper layers. In addition, Ti(C, N) secondary phases and precipitates, such as M<sub>6</sub>C and M<sub>23</sub>C<sub>6</sub> carbides, are observed within the austenitic matrix and confirmed using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). X-ray diffraction (XRD) analysis from the bottom, middle, and top regions of the WAAM build revealed a dominant γ-Ni matrix with a strong columnar dendritic texture and progressive microstructural anisotropy along the build direction. From hardness mapping, the build’s average microhardness ranges from 237 HV at the bottom to 211 HV at the top, nearly matching the characteristics of wrought Inconel 617 as outlined in ASTM B168-19. Anisotropic behavior is evident from the tensile test results, with specimens loaded along the deposition direction exhibiting a higher average ultimate tensile strength (UTS) of 782 ±15 MPa compared to 641 ± 25&#xa0;MPa along the build direction. In all orientations, ductile fracture characteristics, including dimples and voids, are observed, confirming that significant plastic deformation occurred prior to failure. The results demonstrate the importance of building orientation on material performance and highlight the potential of the WAAM process to fabricate Inconel 617 wall structures that are free of defects and possess desirable mechanical and microstructural integrity. While the current study focuses on wall geometries, the findings provide a promising foundation for future development toward more complex component fabrication.</p>

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Microstructure and mechanical performance of Inconel 617 thin wall fabricated via wire arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年11月21日

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  • S. Maheshwaran,
  • A. Rajesh Kannan,
  • N. Siva Shanmugam

摘要

This study presents a comprehensive investigation into the microstructural evolution and mechanical performance of an Inconel 617 wall fabricated using the wire arc additive manufacturing (WAAM) process. Detailed microstructural characterization reveals a gradient in grain morphology along the build direction, driven by variations in thermal history. Equiaxed dendrites and columnar grains due to rapid solidification were noticed near the substrate and are mixed together in the bottom layers, while cellular structures and columnar dendrites are dominant in the middle layers. Columnar and elongated columnar dendrites were observed in the upper layers. In addition, Ti(C, N) secondary phases and precipitates, such as M6C and M23C6 carbides, are observed within the austenitic matrix and confirmed using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). X-ray diffraction (XRD) analysis from the bottom, middle, and top regions of the WAAM build revealed a dominant γ-Ni matrix with a strong columnar dendritic texture and progressive microstructural anisotropy along the build direction. From hardness mapping, the build’s average microhardness ranges from 237 HV at the bottom to 211 HV at the top, nearly matching the characteristics of wrought Inconel 617 as outlined in ASTM B168-19. Anisotropic behavior is evident from the tensile test results, with specimens loaded along the deposition direction exhibiting a higher average ultimate tensile strength (UTS) of 782 ±15 MPa compared to 641 ± 25 MPa along the build direction. In all orientations, ductile fracture characteristics, including dimples and voids, are observed, confirming that significant plastic deformation occurred prior to failure. The results demonstrate the importance of building orientation on material performance and highlight the potential of the WAAM process to fabricate Inconel 617 wall structures that are free of defects and possess desirable mechanical and microstructural integrity. While the current study focuses on wall geometries, the findings provide a promising foundation for future development toward more complex component fabrication.