Wire and arc additive manufacturing (WAAM) is a 3D metal printing technique based on the arc welding process. WAAM is considered to be suitable to produce large-scale metallic components by combining high deposition rate and low cost. WAAM uses conventional welding consumable wires as feedstock. In some applications of steel components, one-off spare parts need to be made on demand from steel grades that do not exist as commercial welding wire. In this research, a specifically produced medium carbon steel (Grade XC-45), metal-cored wire, equivalent to a composition of XC-45 forged material, was deposited with WAAM to produce a thin wall. The specific composition was chosen because it is of particular interest for the on-demand production of heavily loaded aerospace components. The microstructure, hardness, and tensile strength of the deposited part were studied. Fractography studies were conducted on the tested specimens. Due to the multiple thermal cycles during the building process, local variations in microstructural features were evident. Nevertheless, the hardness of the part was relatively uniform from the top to the bottom of the construct. The mean yield/ultimate tensile strength was 620 MPa/817 MPa in the horizontal (deposition) direction and 580 MPa/615 MPa in the vertical (build) direction, respectively. The elongation in both directions showed a significant difference, i.e., 6.4% in the horizontal direction and 11% in the vertical direction. Finally, from the dimple-like structures observed in the fractography study, a ductile fracture mode was determined. Furthermore, a comparison of mechanical properties between WAAM and traditionally processed XC-45, such as casting, forging, and cold rolling was conducted. The results show a more uniform hardness distribution and higher tensile strength of the WAAM deposit using the designed metal-cored wires.

Heating experiments in a wide range of heating rates from 10 to 1200 °C/s and subsequent quenching without isothermal soaking have been carried out on a low carbon steel. The thermal cycles were run on two different cold rolled microstructures, namely ferrite + pearlite and ferrite + martensite. It is shown that the average ferritic grain size, the ferrite grain size distribution, the phase volume fractions and the corresponding mechanical properties (ultimate tensile strength and ductility) after quenching are strongly influenced by the heating rates and the initial microstructure. The ferrite grain size distribution is significantly modified by the heating rate, showing a markedly bimodal distribution after fast annealing. The rise of the heating rate has produced a change in the relative intensities of texture components, favouring those of the cold-deformed structure (RD fibre) over the recrystallization components (ND fibre)

In this paper, the effect of chemical inhomogeneity on the isothermal bainite formation is investigated in medium-carbon low-silicon spring steel by dilatometry and microscopy. The analysis of the microstructure at different times during transformation shows that chemical segregation of substitutional alloying elements resulting from casting strongly affects the bainite formation by retarding the transformation kinetics and limiting the maximum achievable bainite fraction. During holding at temperatures close to and above the martensite start temperature, a homogeneous lower bainitic microstructure can be eventually obtained, whereas at higher temperatures, incomplete bainitic reaction is evident. It was also found that at the early stages of the transformation, differences in the bainite formation kinetics, due to local inhomogeneities in Cr and Mn concentration, result in retardation of the growth of bainite in the high Mn and Cr concentration regions. The calculated difference in driving force for nucleation between the enriched and the depleted areas is not by itself sufficient to explain the microstructures obtained and thus significant influence of growth on bainite formation is observed. Particularly, it was calculated and experimentally observed that Cr partitions in the carbides in the high Mn, Cr regions during the isothermal treatment, limiting the transformation kinetics.