Wire-arc additive manufacturing H13 part: 3D pore distribution, microstructural evolution, and mechanical performances.

Abstract The crack-free H13 block was deposited through additive manufacturing with the cold metal transfer technology. The internal 3D pore distribution, the microstructural evolution, and the mechanical performances were explored. A negligible porosity with dispersive-distribution and spherical-shape below 0.001% guaranteed a sound metallurgical bonding within the as-deposited part. The martensite laths growth direction varied dramatically with a very short position variation, as well as the block-like size-inconsistent δ-ferrite presence in the overlap zone, which were mainly generated by the thermal flux direction from the center to margin within a single arc track. Massive second-phase particles with morphology-diversity and size-nonuniformity were precipitated, indicating a strong dependency with the intrinsic heating treatment. The enhanced microhardness in the body zone was attributed to the martensite strengthening mechanism, while slightly low hardness was produced due to the soft δ-ferrite formation. When compared with the other zones, the enhanced ultimate tensile strength was obtained in the body zone at the expense of tensile ductility, revealing a positive relationship with the rise of hard martensite percentage. This work demonstrated that a crack-free H13 block with limited porosity and desirable mechanical properties was deposited using the present technology, despite the nonhomogeneous microstructures. Highlights • A crack-free H13 block part innovatively and firstly deposited using the robotic CMT technology. • A negligible porosity even below 0.001% guaranteed a sound metallurgical bonding behavior. • Varied microstructural evolution with a very short position variation within a single arc track. • Desirable mechanical performances due to martensite strengthening and precipitation strengthening. [ABSTRACT FROM AUTHOR]