Microstructure and mechanical properties of high strength steel deposits obtained by Wire-Arc Additive Manufacturing

Wire-arc additive manufacturing has become an alternative way to produce industrial parts. In this work 15 kg walls are built with an effective building rate of 4.85 kg/h using an ER100 wire providing good tensile properties and toughness under welding conditions. The thermal evolution of the walls during manufacturing is measured by thermocouples and an IR camera: it depends on process parameters, deposit strategy and the size of the part. The walls are then characterised as deposit and after heat treatment through hardness, tensile and Charpy-V notch tests. The results show a fine microstructure with unexpected retained austenite and coarse allotriomorphic ferrite in the as deposited walls. The final hardness values vary from about 220 to 280 HV2; the yield stress and tensile strength are 520 and 790 MPa, respectively, and a toughness of about 50 J is obtained at room temperature. The heat treatment transforms the retained austenite, leading to an improvement of the yield stress to 600 MPa.