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<p>This study delves into the effects of two Gas Metal Arc Welding (GMAW) derived processes utilized in Wire Arc Additive Manufacturing (WAAM): Cold Metal Transfer (CMT) and Pulsed Metal Inert Gas (MIG), focusing on their influence on the microstructural, mechanical, and corrosion resistance properties of fabricated metallic components. These processes are distinguished by their unique material transfer modes and thermal inputs, significantly affecting the outcome of the manufactured parts. The comparative analysis revealed that CMT produced slightly finer grain structures with an average size of 8.72 ± 0.28&#xa0;μm compared to Pulsed MIG, which had an average grain size of 9.36 ± 0.43&#xa0;μm. In terms of mechanical properties, the CMT process exhibited a marginally higher mean hardness (191.05 HV) than Pulsed MIG (187.72 HV), with a broader spectrum of hardness values. In addition, CMT demonstrated superior toughness, with average values recorded at 115&#xa0;J, compared to 97.55&#xa0;J for Pulsed MIG. The ultimate tensile strength (UTS) and yield strength (YS) were also higher for CMT samples, with UTS at 630&#xa0;MPa and YS at 408&#xa0;MPa, vs. 593&#xa0;MPa and 382&#xa0;MPa for Pulsed MIG, respectively. However, CMT showed a slightly reduced elongation (43%) when compared to Pulsed MIG (48%), indicating a lesser ductility. Corrosion resistance tests indicated lower average corrosion rates for CMT (0.02917 ± 0.003&#xa0;mm/year) in contrast to Pulsed MIG (0.03738 ± 0.005&#xa0;mm/year), suggesting that CMT enhances corrosion resistance alongside mechanical properties. The examination of fracture surfaces confirmed ductile fractures in both processes, with more pronounced dimples observed in CMT samples. These quantitative findings underscore that while both GMAW-derived processes bolster WAAM's efficiency and deposition rates, their differing characteristics can significantly influence the mechanical and structural integrity of the final product. Thereby, the choice between CMT and Pulsed MIG should be guided by the specific requirements of mechanical strength, ductility, and corrosion resistance of the intended application.</p> Graphical abstract <p></p>

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Influence of low heat input on microstructural, mechanical, and corrosion properties in WAAM: a comparative study of cold metal transfer (CMT) and Pulsed MIG techniques

  • 期刊论文

  • 发表日期：

    2025年6月10日

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  • Saboor Fayaz Lone,
  • Dinesh W. Rathod,
  • Sheikh Nazir Ahmad,
  • S. Shiva

摘要

This study delves into the effects of two Gas Metal Arc Welding (GMAW) derived processes utilized in Wire Arc Additive Manufacturing (WAAM): Cold Metal Transfer (CMT) and Pulsed Metal Inert Gas (MIG), focusing on their influence on the microstructural, mechanical, and corrosion resistance properties of fabricated metallic components. These processes are distinguished by their unique material transfer modes and thermal inputs, significantly affecting the outcome of the manufactured parts. The comparative analysis revealed that CMT produced slightly finer grain structures with an average size of 8.72 ± 0.28 μm compared to Pulsed MIG, which had an average grain size of 9.36 ± 0.43 μm. In terms of mechanical properties, the CMT process exhibited a marginally higher mean hardness (191.05 HV) than Pulsed MIG (187.72 HV), with a broader spectrum of hardness values. In addition, CMT demonstrated superior toughness, with average values recorded at 115 J, compared to 97.55 J for Pulsed MIG. The ultimate tensile strength (UTS) and yield strength (YS) were also higher for CMT samples, with UTS at 630 MPa and YS at 408 MPa, vs. 593 MPa and 382 MPa for Pulsed MIG, respectively. However, CMT showed a slightly reduced elongation (43%) when compared to Pulsed MIG (48%), indicating a lesser ductility. Corrosion resistance tests indicated lower average corrosion rates for CMT (0.02917 ± 0.003 mm/year) in contrast to Pulsed MIG (0.03738 ± 0.005 mm/year), suggesting that CMT enhances corrosion resistance alongside mechanical properties. The examination of fracture surfaces confirmed ductile fractures in both processes, with more pronounced dimples observed in CMT samples. These quantitative findings underscore that while both GMAW-derived processes bolster WAAM's efficiency and deposition rates, their differing characteristics can significantly influence the mechanical and structural integrity of the final product. Thereby, the choice between CMT and Pulsed MIG should be guided by the specific requirements of mechanical strength, ductility, and corrosion resistance of the intended application.

Graphical abstract