Investigations on Dry Sliding Wear Behavior of a Wire Arc Additively Manufactured Nickel-Based Superalloy

Abstract

Wire arc additive manufacturing (WAAM) is a low-cost method of fabricating large components from advanced materials such as nickel-based superalloys. Nickel-based superalloys have varied industrial applications and suit the WAAM method due to their excellent weldability when used in conjunction with metal inert gas welding equipment used in the current study. All WAAM specimens were subjected to a standard dry sliding wear test to examine wear behavior. During the wear study, load, sliding velocity, and sliding distance were all considered for both wrought and WAAM alloy. The lowest wear was observed at a lower load and higher sliding velocity, whereas the highest wear was observed at a higher load and lower sliding velocity. Wear mechanisms and wear debris corresponding to lowest and highest wear conditions were also investigated. The transition from lowest to highest wear rate in both alloys was attributed to the transition from abrasive to adhesive and delamination wear mechanisms. Microstructural analysis revealed that the nickel-based WAAMed alloy had an equiaxed dendritic structure, whereas the nickel-based wrought alloy had a cellulose structure. Both specimens had a stable austenite structure in the Ni-Fe-Cr phase, as determined by X-ray diffraction analysis. The X-ray diffraction line profile analysis technique by the Williamson-Hall relationship revealed that WAAM alloys have higher microstrain, higher dislocation density, and smaller crystallite size when compared to wrought alloys. The experimental results showed a 23% increase in hardness and a considerable improvement in wear resistance in the WAAMed alloy compared to the wrought alloy.

Graphical Abstract

Keywords:

• Wire arc additive manufacturing
• nickel-based superalloy
• X-ray diffraction analysis
• dry sliding wear
• wear mechanisms

Conflict of interest

The authors declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.