The manuscript demonstrates the structure and the mechanical behavior of a material manufactured by multilayer arc deposition. Three-dimensional printing was performed using OK Autrod 13.14 wire on a substrate of heat-resistant 12Cr1MoV steel in the standard gas metal arc welding (GMAW) mode and in the coldArc mode with reduced heat input. The printed materials have 40–45% higher strength and 50–70% lower ductility compared to the substrate. The microhardness of the printed materials is higher than the substrate, but it is reduced at the transition regions between the deposited layers. These regions have been studied using optical microscopy and digital image correlation. Such layer boundaries are an additional factor in reducing the plasticity of the material. The increase in strength and decrease in ductility for printed materials compared to the ferrite–pearlitic substrate is associated with a high cooling rate and the formation of a mixture of acicular and allotriomorphic ferrite, which have higher hardness. The structure of the obtained layers along the height is non-uniform and undergoes changes during the deposition of new layers. The main difference between the 3D printing modes is the reduced heat input in the coldArc mode, which results in less heat accumulation and faster cooling of the wall. Thus, a more dispersed and solid structure was formed compared with GMAW. It was concluded that the cooling rate and the level of heat input are the main factors affecting the structure formation (martensitic, bainitic, or ferritic), the height and quality of the surface, and the mechanical properties of the printed wall.

Defect-free thin-walled samples were built using wire arc additive manufacturing (WAAM) combined with the “coldArc” deposition technique by feeding a Ti-6Al-4V welding wire and using two deposition strategies, namely with and without the welding torch weaving. The microstructures formed in these samples were examined in relation to mechanical characteristics. The arc torch weaving at 1 Hz allowed us to interfere with the epitaxial growth of the β-Ti columnar grains and, thus, obtain them a lower aspect ratio. Upon cooling, the α/α′+β structure was formed inside the former β-Ti grains, and this structure proved to be more uniform as compared to that of the samples built without the weaving. The subtransus quenching of the samples in water did not have any effect on the structure and properties of samples built with the arc torch weaving, whereas a more uniform grain structure was formed in the sample built without weaving. Quenching resulted also in a reduction in the relative elongation by 30% in both cases.

The work presents the study of structure and mechanical properties anisotropy of a metal wall obtained using electric arc wire 3D printing (WAAM) with ER70S-6 wire. The layers were deposited in the protective gases of carbon dioxide and argon. As a result of structural studies, it was found that the internal structure of the model product in form of a wall can be divided into three zones. Repeated heating, cooling cycles and degree of accumulated heat influence the formation of different wall zones. As a result of rapid heat removal to the substrate during deposition of the first layers, the wall base (zone 1) contains large elongated grains with acicular ferrite structure. The wall middle part (zone 2) consists of ferrite-pearlite structure, which was formed as a result of recrystallization under conditions of repeated heating and cooling during 3D printing. The size of ferrite grains in zone 2 varies from 11 to 16.3 µm with increasing the number of layers. The gradual accumulation of heat during 3D printing led to the formation of structures in zone 3 under conditions of overheating and a reduced cooling rate. As a result, the wall upper part (zone 3) consists of large ferrite grains (up to 29.8 μm), sorbite, and a small proportion of Widemanstatten ferrite and acicular ferrite. It is shown that the most uniform level of mechanical characteristics (σ_0.2 = 340 MPa, σ_u = 470 MPa, ε = 28 %) correspond to the samples cut from zone 2 in a direction parallel to 3D prin­ting direction. The samples cut in the vertical direction relative to 3D printing and from zone 3 show the lowest level of microhardness and mechanical characteristics (σ_0.2 = 260 MPa, σ_u = 425 MPa, ε = 20 %).