Wear Characteristics of Dissimilar SDSS 2507–IN 718 Parts Fabricated by Cold Metal Transfer-Based Wire Arc Additive Manufacturing

Metals may be efficiently additively manufactured using wire-arc additive manufacturing, often known as Wire-Arc Additive Manufactured (WAAM) process. The use of a cold metal transfer (CMT) machine allows the achievement of the desired outcome due to its low heat input and minimal spatter generation. A single thin-walled structure was created by fabricating Super Duplex Stainless Steel (SDSS) 2507 and Inconel (IN) 718 utilizing a filler wire with a diameter of 1.2 mm. This manuscript presents the summary of wear on the dissimilar alloy wall manufactured using the WAAM technique, subjected to dry sliding under extreme loading conditions. Wear testing was conducted in a dry, unlubricated environment using a standard high-load ball-on-disc tribometer. Wear-rate and coefficient of friction are minimum at low loading conditions for SDSS 2507. Energy-dispersive X-ray spectroscopy (EDS) verified fine element disintegration at the IF without composition change. The microstructure investigation indicates epitaxial grain growth in the build direction and non-equilibrium microstructures in the deposited layer. Scanning electron microscopy (SEM) of SDSS 2507 shows austenite and ferrite in the lower part, while SEM of IN 718 reveals columnar and cellular crystals with white laves phases formed due to the segregation of Nb and Mo elements. Worn surfaces reveal grooving, delamination, delamination cracks, ploughing grooves, parallel grooves, and particle adherence, confirming adhesion and abrasive wear mechanism. The absence of oxygen elements in EDS analysis shows that there is an absence of oxidative wear.