Objective: To analyze the efficiency of a hybrid manufacturing process that combines arc and wire additive manufacturing (WAAM) with hot forging, using the UTP DUR 600 consumable, evaluating its effects in the microstructure and mechanical properties of pen type hammers. Theoretical Structure: Additive manufacturing (AM) allows for the rapid and precise creation of complex projects, making the WAAM technique a promising alternative for its ability to deposit large volumes of material. However, its lower surface precision can be compensated by subsequent processes, such as hot forging — a technique consolidated in the industry for improving the mechanical properties of two metals by means of plastic deformation at high temperatures. Method: Metal pieces are manufactured by WAAM with the UTP DUR 600 electrode arame, deposited layer by layer, and subsequently submeted into the forging by quente. Avaliaram-se alterações microestruturais, including the recrystallization dynamic, or refinement of grains, or alignment of the fibers of the material and the distribution of phases. The effects of temperature and deformation rates are also considered. The resistance to abrasive wear was validated with a non-flat base of the deposit path. Results and Discussion: The forging caused dynamic recrystallization and significant alterations in the microstructure of the UTP DUR 600 liga, including the refinement of grains and the realinhamento of the fibers of the material. These changes contribute to the increase in mechanical resistance and tenacity of parts. Abrasive wear resistance also presents advantages, associated with the planing of the deposition process and the forging conditions. Research Implications: The study demonstrates that the combination of WAAM with quente forging can overcome surface precision limitations of additive manufacturing, offering parts with better mechanical properties. A detailed analysis of the process variables contributes to the optimization of industrial parameters in applications that demand high wear resistance. Originality/Value: The research presents an innovative approach to integrating additive manufacturing by arame arc with hot forging, investigating its microstructural and mechanical effects in a high hardness league. This combination is still little explored in the literature, especially in the manufacturing of fine components, offering significant advances in the performance and durability of two components.

Objective: The objective of this study is to investigate the effects of hot forging on the microstructure and microhardness of a component manufactured by additive manufacturing (AM), specifically an eyebolt produced by the WAAM (Wire and Arc Additive Manufacturing) process, seeking to refine the grain size, relieve residual stresses and eliminate porosities. Theoretical Framework: Additive manufacturing (commonly called 3D printing) has been gaining ground in the manufacturing of parts and components, allowing layer-by-layer construction, useful for complex designs and rapid prototyping. The WAAM process stands out for its high material deposition rate, although it presents lower surface precision, requiring finishing by machining. The microstructure of metals printed by AM, such as carbon steel, is characterized by coarse grains, residual stresses and porosities, which can compromise the performance of the final component. Method: In this study, an eyebolt in carbon steel was manufactured by AM (WAAM process). Then, the component was subjected to hot forging. The analysis focused on evaluating the microstructure and microhardness of the samples before and after forging, seeking to verify the effect of the hybrid process (AM + forging). Results and Discussion: The microstructural analysis revealed that the forged sample presented significantly smaller grains compared to the part that was only printed. Regarding microhardness, the values ​​were also higher in the hybrid condition (207 HV) compared to the material that was only printed (161 HV), a result that was consistent with expectations, due to the grain refinement promoted by hot forging. Research Implications: The results indicate that the combination of additive manufacturing with hot forging can mitigate metallurgical deficiencies typical of printed components, such as coarse grains and porosities, in addition to improving mechanical properties, such as hardness. In addition, the use of AM allows the manufacture of preforms, reducing material waste and the need for tools in the forming process. Originality/Value: This work proposes an innovative hybrid approach, combining additive manufacturing and hot forging, as a strategy to improve the metallurgical and mechanical properties of metal components. This combination optimizes resources, promotes sustainability in the use of raw materials and expands the potential of AM for more demanding structural applications.

Objective: The objective of this study is to analyze additive manufacturing by metal deposition, mechanically validating the efficiency of ER 310 stainless steel, in order to understand its metallurgical and structural behavior, in addition to establishing ideal operating parameters for layer-by-layer deposition. Theoretical Framework: Additive manufacturing (AM) is a growing manufacturing technique, known for reducing material waste and improving delivery times, in addition to contributing to sustainability by reducing the carbon impact. The technique involves the superposition of metal layers, integrating knowledge from mechanical engineering, metallurgy, welding and automation. ER 310 stainless steel, used in this study, is widely applied due to its high resistance to oxidation and heat. Method: The metal deposition process was performed using a CNC arm programmed to operate with continuous and controlled movement, forming a wall composed of several successive layers. Material characterization included chemical analysis by optical emission spectrometry and Vickers microhardness testing with 15 indentations. Metallographic analysis was also performed to observe the microstructure and thermal monitoring of the molten pool during deposition. Results and Discussion: The results demonstrated that the chemical composition of the deposited material is within the expected limits for ER 310 wire. The average microhardness was 191 HV, revealing uniformity throughout the layers. The metallographic analysis indicated a predominantly austenitic microstructure, with small dark spots attributed to the possible formation of chromium carbide, due to the high chromium content of the material. Thermal monitoring indicated temperatures in the molten pool around 1900 °C, gradually decreasing with each pass, which influences the thermal stability and the final microstructure. Research Implications: This study provides important subsidies for the development of technical parameters in the additive manufacturing of stainless alloys, especially in applications where thermal control and metallurgical integrity are essential. The implications include sectors such as advanced metallurgy, manufacturing of corrosion-resistant and high-temperature components, and contributes to the optimization of processes with less material waste. Originality/Value: This research contributes to the literature by exploring the deposition of ER 310 stainless steel using additive manufacturing with real-time thermal monitoring, offering unprecedented data on the hardness, microstructure, and thermal stability of the process. The value of the research lies in the possibility of establishing new sustainable and technically viable manufacturing routes for high-performance industrial applications.

Introduction: Additive manufacturing (AM) of metals emerged with the aim of complementing and even replacing existing manufacturing techniques. There is not yet a wide range of materials that can be processed using this technology, but it is already possible to process titanium, aluminum, nickel, cobalt, chromium, stainless steel, and maraging steel alloys. Objective: The objective of this study is to investigate the additive manufacturing process by localized fusion for E71T-1 and ER70S-6 alloys, with the aim of comparing their mechanical and metallurgical characteristics. Theoretical Framework: Additive manufacturing has advantages such as raw material savings and the development of complex parts, which, using current techniques, would require more than one process to complete the product. Method: For the study, the parts were produced using a welding robot. The materials studied were the AWS A5.20 E71T-1 consumable and the AWS A5.18 ER70S-6 consumable. The test specimens were characterized by tensile and hardness tests and metallographic analysis. Results and Discussion: Microhardness tests indicated that both deposited materials exhibit homogeneous hardness. Metallographic analyses revealed that E71T-1 has smaller grain sizes than ER70S-6. Research Implications: Understanding the thermal influence on carbon precipitation contributes to the improvement of process parameters in arc additive manufacturing, aiming at better microstructural control and mechanical performance of the produced parts. Originality/Value: This study addresses a specific and little-explored aspect of additive manufacturing of metals, evaluating the efficiency of the methods used and quality control.

Em decorrência do avanço tecnológico no ramo metal mecânico, bem como, contribuir no ramo científico para tal, se traz neste artigo um estudo sobre os comportamentos mecânicos para o eletrodo de soldadura UTP 7200D, mais especificamente, entender o comportamento para este material em relação ao desgaste abrasivo e qual sua estrutura metalográfica. Processos de soldagem representam um desafio devido à grande variedade de ligas disponíveis e são amplamente utilizados nas indústrias metalúrgicas, visando união de materiais e incremento de camada extra de revestimento almejando ganhos de rendimentos, onde sobre um núcleo de material menos resistente, recobre-se, este, por um material com propriedades superiores, estabelecendo ganhos no quesito custo X benefício. O conhecimento das características tribológicas dos materiais sujeitos ao desgaste por abrasão é fundamental para a otimização e definição dos elementos de máquinas, e é fator determinante na quantificação da vida útil dos dispositivos mecânicos. Neste artigo, avaliaram-se as propriedades de resistência ao desgaste abrasivo do revestimento depositado através do eletrodo de solda UTP 7200D (sobre um substrato de aço SAE 1020) e estudou-se sua estrutura metalográfica. Este eletrodo, usualmente é indicado para serviços onde são exigidas as propriedades do aço manganês austenítico, sob condições de impacto elevado, compressão, atrito e abrasão moderada, proporcionando elevada resistência a trincas. As amostras foram submetidas a ensaio de desgaste utilizando um abrasômetro do tipo roda de borracha, padronizado pela norma ASTM G65-91 e obtido os valores de perda de massa. As propriedades mecânicas de um material estão relacionadas a sua microestrutura, sendo de grande importância conhecê-las qualitativamente, avaliando o seu comportamento microestrutural e sua composição química em diferentes zonas, avaliando-se a constituição e estrutura dos metais com o objetivo de relacioná-los com as propriedades mecânicas e processos de fabricação. Essa estrutura revela os agregados e fases de uma liga metálica em função de sua composição química ou processos de transformação aplicados à mesma. A partir dos resultados obtidos foi possível afirmar que o eletrodo UTP 7200D não obteve resistência ao desgaste abrasivo para trabalhos com revestimento. O material depositado obteve a perda média de 2,92 gramas, enquanto comparado com a literatura um metal utilizado como britador com cobertura de carboneto de tungstênio perde em torno de 0,4 gramas no mesmo tempo aplicado aos dois casos. Entretanto, para avaliação microestrutural, a região soldada apresentou dendritas que se formam quando o material solidifica em movimento, fenômeno esse que caracteriza um processo complexo na solidificação com este eletrodo. Já para a região da fronteira entre metal de base e metal depositado, é possível perceber a ferrita de Widmanstätten. Este tipo de ferrita é característica de soldagem com superesfriamento, onde possui dureza maior comparado com a ferrita poligonal, o que nem sempre é desejado devido ao aumento da fragilidade da zona afetada pelo calor.

Objective: This study aims to investigate the joining region between two materials — a steel produced by additive manufacturing and a rolled aluminum — with the purpose of developing a manufacturing alternative that uses lighter materials and has less environmental impact. Theoretical Framework: The study is based on the principles of forging at different temperature combinations, exploring the interaction between an element manufactured by a relatively recent additive manufacturing technology, in order to improve the process. Aspects such as metallography of the elements, characterization of the deposited material and analysis of the union between the two materials were considered to better understand the variables involved in production. Method: The methodology adopted for this research involves exploratory research seeking to deepen knowledge about the production of bimetallic elements, using metallographies of the constituents present in this union. Eight test pieces and appropriate tooling were developed in order to develop the samples. Results and Discussion: The results obtained revealed localized cracks in some samples, possibly caused by uneven contraction during cooling of the materials. The temperature of the steel promoted few microstructures near the bimetallic boundary. The temperature of 550 ºC for forging the deposited steel and aluminum at room temperature should be reviewed due to the difference in contraction during cooling after warm forging. The union between the two metals occurred basically by mechanical locking, which occurred during forging. Research Implications: The results of this work demonstrate the applicability of replacing traditional mechanical elements with the manufacture of forged bimetallic components. Furthermore, the research raises an issue regarding the reduction of pollutant emissions, sustainability and competitiveness in various segments of the industry. Originality/Value: This study contributes to the literature by presenting an efficient alternative for the production of parts by additive manufacturing, integrated with another material through forging. This approach favors the reduction of costs, fuel consumption and environmental impacts in different sectors of the industry. The relevance of the research is evident in the combination of additive manufacturing with the forging of bimetallic elements, bringing significant benefits to the automotive industry — both combustion and electric vehicles —, aerospace and other industrial segments.