Nizhny Novgorod State Technical University named after R. E. Alekseev, Nizhny Novgorod, Russia

Yu. G. Kabaldin, Dr. Eng., Prof., Dept. of Mechanical Engineering Technology and Equipment, Institute of Industrial Technologies in Mechanical Engineering
M. S. Anosov, Cand. Eng., Associate Prof., Dept. of Mechanical Engineering Technology and Equipment, Institute of Industrial Technologies in Mechanical Engineering, e-mail: anosov.ms@nntu.ru
M. A. Chernigin, Engineer, Dept. of Mechanical Engineering Technology and Equipment, Institute of Industrial Technologies in Mechanical Engineering, e-mail: honeybadger52@yandex.ru
Yu. S. Mordovina, Postgraduate Student, Lead Engineer, Institute for Retraining of Specialists, Assistant, Dept. of Mechanical Engineering Technological Complexes, Institute of Industrial Technologies in Mechanical Engineering, e-mail: ips4@nntu.ru

The rapid development of additive manufacturing technologies has led to an increased interest in this field not only among scientists but also in the industry. Despite the vast amount of knowledge accumulated on these technologies, the impact of surfacing conditions on the chemical composition, hardness, and structural formation of low-carbon steel during additive electric arc welding has not been fully explored. This study aims to investigate the effect of different electric arc welding modes on the microstructure and properties of 08KhMFA steel using WAAM (wire arc additive manufacturing) technology. It has been established that the process parameters, such as current (I = 120-200 A), voltage (U = 18-27 V), and energy of surfacing (Q = 520-1300 J/mm), determine the chemical composition, hardness, and microstructural features of the deposited metal. Optical emission spectral analysis has revealed that the maximum burnout of alloying elements occurs at U = 27 V and Q = 1300 J/mm, with V reaching a maximum of 28 % and C reaching a maximum of 34 %. However, minimal losses were observed in modes with U = 18 V, where carbon and vanadium exhibit the most active burnout, while molybdenum decreases the least actively for all modes. During the measurement of microhardness in the deposited samples, it was found that as the linear energy of deposition increases, the average hardness decreases from 258 to 216 HV0.5. This may be due to processes such as recrystallization and carbon burnout during the process. The most uniform hardness distribution across the height of the sample was observed at U = 18 V. Metallographic analysis revealed a three-band heterogeneity in the height of the samples. The first band is ferrite-perlite, near the substrate. The middle zone has a pronounced grain diversity, and the upper layers have a Widemannstett structure. Regardless of the surfacing mode, very fine grains were detected (9-10 points according to GOST R ISO 643-2015). Optimal modes (U = 18 V, Q = 520-860 J/mm) ensure minimal burnout of alloying elements and a uniform hardness distribution.

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