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Influence of Microstructural Characteristics on the Mechanical and Wear Behavior of Wire Arc Additive Manufactured and Cast Eutectic Al-Si Alloy

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Abstract

The present study investigates the dry sliding wear behavior of Wire arc additive manufactured (WAAM) eutectic Al-Si alloy, with a particular focus on the effects of solidification and microstructural characteristics on wear behavior. Microstructural analysis indicated that the secondary dendrite arm spacing (SDAS) for the WAAM sample was three times higher than that of the cast sample. The WAAM sample exhibited thin, long columnar dendrites, while the cast samples displayed coarse and ripened dendrites. Furthermore, EBSD analysis revealed that the WAAM sample had a higher percentage (88.6%) of low-angle grain boundaries (LAGBs), contributing to their increased strength compared to cast samples with 78.6% LAGBs. The maximum wear rate of 5.45 × 10–6 g/m was observed at a normal load of 25 N and a sliding speed of 1.1 m/s with a coefficient of friction (CoF) of 0.59 for WAAM samples while casting samples exhibited a lower wear rate of 3.06 × 10–6 g/m and a CoF of 0.55 under identical conditions. Delamination, severe adhesion, and abrasion were the primary wear mechanisms under maximum wear rate test conditions. The subsurface of WAAM samples contained a mechanical mixed layer (MML), while cast samples revealed a stable thin oxide layer. The study found that samples with higher texture strength and lower Taylor factor (TF) values were more prone to damage.

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All data generated or analyzed during this study are included in this article. However, if any additional data is required, they can be obtained from the corresponding author, M Hemachandra, upon reasonable request.

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Acknowledgements

The authors would like to acknowledge the financial support from the Aeronautics Research and Development Board (AR&DB), Government of India.

Funding

This work was supported by the Aeronautics Research and Development Board (AR&DB), Government of India, under Grant No. ARDB/01/2031958/M/I.

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  1. Mechanical Engineering Department, National Institute of Technology Warangal, Warangal, Telangana, 506004, India

    M. Hemachandra, Shivraman Thapliyal, Babar Pasha Mahammod & Adepu Kumar

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M Hemachandra*: Conception, experimental design, carrying out experiments and manuscript composition. Shivraman Thapliyal: Conception, experimental design, carrying out experiments and manuscript composition. Babar Pasha Mahammod: Carrying out experiments and manuscript composition. Adepu Kumar: Experimental design and manuscript composition.

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Hemachandra, M., Thapliyal, S., Mahammod, B.P. et al. Influence of Microstructural Characteristics on the Mechanical and Wear Behavior of Wire Arc Additive Manufactured and Cast Eutectic Al-Si Alloy. Silicon 16, 2441–2463 (2024). https://doi.org/10.1007/s12633-024-02848-6

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