Wire arc additive manufacturing of NiFe alloy/ductile cast iron bimetallic structure; phase transformations, microstructure and crystallographic texture

Abstract

Wire arc additive manufacturing (WAAM) is a significant area of interest within the field of additive manufacturing (AM). In the present research, WAAM technology was employed to deposit a Ni-based alloy on a ductile cast iron substrate to fabricate a bimetallic structure of Ni-45 %Fe alloy and ductile cast iron. Scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), electron back scattered diffraction (EBSD) and X-ray diffraction (XRD) were used to study phase transformations, microstructure and crystallographic texture development in interfacial regions as well as deposited material. The mechanical properties were also studied using micro-hardness and profilometry-based indentation plastometry (PIP) measurements. The results showed that a wide variety of phases are generated within the heat-affected zone (HAZ) and partially melted zone (PMZ). These phases form complex microstructures with single and double shell morphology. The deposited alloy has a face-centred cubic (FCC) structure, with some carbides and graphite that are formed during the solidification of the first deposited layer. The compositional changes were also observed across the interface. The texture of the deposited alloy showed around 30° deviation from 〈100〉 II building direction due to the shape and overlap of the melt pools. The present results provide a better understanding of interface development mechanisms during WAAM of bimetallic structures. The peak of the hardness across the interface was observed in PMZ because of the formation of a martensitic matrix. The PIP measurements showed that the ${\sigma }_y$ and the $\mathrm{UTS}$ of deposited alloy are lower than the cast iron base metal.