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<p>Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technique for producing large nickel-based super alloy components, although controlling microstructure, mechanical properties, and segregation of Nb/Mo due to repeated heating remains challenging. Unlike conventional WAAM studies that primarily focus on material processing variables, this work specifically addresses deposition path strategy as a thermal management and structural control approach rather than a material fabrication problem. In this work, cylindrical ER NiCrMo-3 (Equivalent to Inconel 625) components were fabricated using a 1.2&#xa0;mm diameter filler wire, employing four different deposition strategies. They are Raster 45°, Raster 90°, Zigzag 45°, and Zigzag 90° increment for each layer. A systematic comparison shows that the Raster 45° increment strategy consistently outperforms the others, achieving a tensile strength of 547&#xa0;MPa and an optimum average hardness of 220.84&#xa0;HV with uniformity index of 0.90. Nb/Mo segregation tendency examination using Scanning Electron Microscopy with Energy-Dispersive X-ray Spectroscopy (SEM–EDS) reveals moderate relatively balanced. Microstructural examination using Field-Emission Scanning Electron Microscopy (FE-SEM) and Electron Backscatter Diffraction (EBSD) reveals fine columnar dendrites along with a significant equiaxed grain fraction, which supports the improved mechanical response. X-ray diffraction (XRD) analysis shows well defined diffraction peaks corresponding to stable γ-phase, with no significant peak broadening, suggesting relatively lower lattice strain compared to other. Overall, EBSD, FESEM, XRD, SEM–EDS, micro hardness and tensile test results are correlated strongly on the deposition pattern angular increment between layers. The results indicate that layer-wise rotational path planning influences the metallurgical uniformity and mechanical response of laboratory scale thick cylindrical WAAM components. Although the thermal behaviour is interpreted indirectly in the present work, the combined FE-SEM, EBSD, XRD, SEM–EDS, hardness, and tensile results suggest that the Raster 45° strategy provides a more favourable path condition for producing structurally uniform ER NiCrMo-3 cylindrical components. The results demonstrate that a raster 45° deposition strategy provides an effective and practical path strategy for fabricating high-quality thick cylindrical ER NiCrMo-3 components using WAAM.</p> Graphical abstract <p></p>

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Layer-wise rotational deposition path strategies for microstructural uniformity and mechanical integrity in WAAM cylindrical components

  • 期刊论文

  • 发表日期：

    2026年7月21日

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  • Tamil Prabakaran Samaraj,
  • Jerome Savarimuthu,
  • Thirumal Pattabi

摘要

Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technique for producing large nickel-based super alloy components, although controlling microstructure, mechanical properties, and segregation of Nb/Mo due to repeated heating remains challenging. Unlike conventional WAAM studies that primarily focus on material processing variables, this work specifically addresses deposition path strategy as a thermal management and structural control approach rather than a material fabrication problem. In this work, cylindrical ER NiCrMo-3 (Equivalent to Inconel 625) components were fabricated using a 1.2 mm diameter filler wire, employing four different deposition strategies. They are Raster 45°, Raster 90°, Zigzag 45°, and Zigzag 90° increment for each layer. A systematic comparison shows that the Raster 45° increment strategy consistently outperforms the others, achieving a tensile strength of 547 MPa and an optimum average hardness of 220.84 HV with uniformity index of 0.90. Nb/Mo segregation tendency examination using Scanning Electron Microscopy with Energy-Dispersive X-ray Spectroscopy (SEM–EDS) reveals moderate relatively balanced. Microstructural examination using Field-Emission Scanning Electron Microscopy (FE-SEM) and Electron Backscatter Diffraction (EBSD) reveals fine columnar dendrites along with a significant equiaxed grain fraction, which supports the improved mechanical response. X-ray diffraction (XRD) analysis shows well defined diffraction peaks corresponding to stable γ-phase, with no significant peak broadening, suggesting relatively lower lattice strain compared to other. Overall, EBSD, FESEM, XRD, SEM–EDS, micro hardness and tensile test results are correlated strongly on the deposition pattern angular increment between layers. The results indicate that layer-wise rotational path planning influences the metallurgical uniformity and mechanical response of laboratory scale thick cylindrical WAAM components. Although the thermal behaviour is interpreted indirectly in the present work, the combined FE-SEM, EBSD, XRD, SEM–EDS, hardness, and tensile results suggest that the Raster 45° strategy provides a more favourable path condition for producing structurally uniform ER NiCrMo-3 cylindrical components. The results demonstrate that a raster 45° deposition strategy provides an effective and practical path strategy for fabricating high-quality thick cylindrical ER NiCrMo-3 components using WAAM.

Graphical abstract