M. Karthikeyan, R. Selvabharathi
Background In the present research effort, single-layer deposition was used to fabricate high-strength alloy plates for wire arc additive manufacturing (WAAM) procedures using 2205 (FeCr-WAAM), 66Co26Cr5WC (CoCr-WAAM), and Fe-interface metallic (Fe-IM). The study aimed to improve the mechanical characteristics and surface morphology of high-strength alloy plate samples by comparing WAAM samples with those coated using plasma spray, focusing on microstructure, hardness, porosity faults, and wear resistance. Methods Microstructural analyses were carried out using SEM and EBSD techniques. For 2205 filler wire samples, FeCr₂O₄ multiferroic spinel, γ’-austenite crystal (AC), and CrCo biomaterial phases were observed. The 66Co26Cr5WC filler showed Co-rich solid structures (CSS), martensitic ferrite transformation (MFT), and CrO₃ crystal structures under varying heat inputs. EBSD revealed that Fe-IM samples coated with plasma spray exhibited NiFe₂O₄ cubic ferromagnetic oxide, MnCr₂O₄, and MnO₄ lattice structures, while uncoated Fe-IM samples showed NiFe₂O₄, Fe₃O₄, and CoFe₂O₄ phases. Bulk texture analysis indicated that interface metallic coated surfaces (Fe-IMC 1 <200>, Fe-IMC 2 <022>, Fe-IMC 3 <111>, and Fe-IMC 4 <311>) contained more nickel and cobalt compared to outer surfaces. Inner surface layers of Fe-IM 1 <001>, Fe-IM 2 <111>, and Fe-IM 3 <110> showed multiferroic CoFe structure and α-austenite crystal structure. Wear resistance and corrosion studies were performed on WAAM, WAAM-IM, and WAAM-C sample surfaces. Significant findings Compared to the 2205 filler wire samples, the Fe-IM coated samples exhibited a 14 % higher hardness value. The NiFe₂O₄ structure was found to provide protection to both inner and outer surface layers of the samples. These findings suggest that interface metallic coating and plasma spray treatment significantly enhance the mechanical and surface characteristics of WAAM-fabricated high-strength alloy components.