Effect of WAAM Process Parameters on Structure and Mechanical Properties of Low-Carbon Steel Thin Walls Margarita Klimova, Konstantin Nasonovskiy, Dmitrii Mukin, Ilya Astakhov, Artem Voropaev, et al. Journal of Manufacturing and Materials Processing, 2026 Wire Arc Additive Manufacturing (WAAM) has emerged as a promising additive manufacturing technique due to its high deposition rate and low material cost. WAAM is increasingly adopted in various industries for the production of large-scale metal components, yet optimizing productivity without sacrificing mechanical integrity remains a critical challenge, particularly for low-carbon steels. This study systematically investigates the influence of key WAAM parameters—welding current (100–350 A) and travel speed (5–30 mm/s) on the deposition stability, microstructure, and mechanical properties of thin walls made of low-carbon Fe–0.09 C–1.10 Cr–1.47 Mn–0.59 Si–0.56 Mo–0.11 Ni–0.23 V steel. A stable processing window for defect-free wall fabrication was established for currents of 100–250 A, while higher currents of 300–350 A resulted in melt pool instability and geometrical distortions due to excessive heat input. Microstructural characterization revealed a dual-phase structure consisting of allotriomorphic ferrite (ALF) and acicular ferrite (AF) in all samples. The microstructural evolution was critically governed by variations in the cooling time in the critical temperature range of 800 °C to 500 °C (t8/5) within the thermal cycles, a direct consequence of the heat input quantified through volumetric energy density. Low heat input at 100 A, 5 mm/s promoted a microstructure with minimal ALF fraction of ~10%, whereas high heat input at 350 A, 30 mm/s induced significant ferrite recrystallization and coarsening, increasing ALF fraction to ~55%. These microstructural changes directly affected mechanical properties: YS/UTS decreased from 512 MPa/668 MPa to 401 MPa/602 MPa, respectively. Concurrently, the deposition rate increased substantially from ~1.6 kg/h to ~6.3 kg/h. The results demonstrate a critical trade-off between productivity and mechanical performance, providing a practical framework for parameter selection in WAAM-fabricated low-carbon steel components.
Optimization of Strength and Plasticity in Layered Aluminum Composites Through High-Pressure Torsion Treatment Alexey Evstifeev, Aydar Mavlyutov, Artem Voropaev, Darya Volosevich Metals, 2024 The development of high-strength aluminum alloys with improved ductility is a crucial challenge for modern materials science, as high strength and ductility tend to be mutually exclusive properties. In this work, the composite material was fabricated using wire arc additives manufactured from AA1050 (commercially pure aluminum) and AA5056 (an Al–Mg system alloy) aluminum alloys. It was demonstrated that the addition of a lower-strength material into a high-strength matrix enhances the potential for deformation localization and results in an increased plasticity of the composite material. A further strengthening of the composite material was achieved through its deformation by a high-pressure torsion (HPT) technique. The mechanical properties of the material were thoroughly investigated before and after the HPT treatment. Static strength and plasticity were analyzed as a function of the deformation degree. Microstructural analysis was performed using scanning electron microscopy and X-ray diffraction. The optimal deformation route, providing the best combination of mechanical properties, was experimentally identified, along with key microstructural parameters of the formed composite with a bimodal grain structure. A deformation level corresponding to 36% of shear stress provides a yield stress of up to 570 MPa, an ultimate tensile strength of up to 664 MPa, and a relative elongation to failure of up to 7%. As a result of the deformation treatment, characteristic substructures with dimensions of ~250 nm and >1000 nm are formed, with a volume ratio of approximately 80/20.
Mechanical properties of layered composites based on AA1050 and AA5056 aluminum alloys produced by WAAM technology A D Evstifeev, B A Yakupov, A M Mavlyutov, D V Volosevich, A A Voropaev Journal of Physics Conference Series, 2024 The possibility of producing layered aluminum materials using wire-arc additive manufacturing (WAAM) technology has been investigated. Deformation characteristics of composites based on AA1050 and AA5056 aluminum alloys are considered. Mechanical tests of specimens with different orientations of AA1050 layers in AA5056 alloy matrix are presented. The results are analysed in the light of the structural characteristics of the composites.
The Effect of Severe Plastic Deformation on the Microstructure and Mechanical Properties of Composite from 5056 and 1580 Aluminum Alloys Produced with Wire Arc Additive Manufacturing Aydar Mavlyutov, Alexey Evstifeev, Darya Volosevich, Marina Gushchina, Artem Voropaev, et al. Metals, 2023 In this study, a composite with alternate layers of 5056 and 1580 alloys was manufactured with wire arc additive manufacturing technology. It is shown that increased strength characteristics of composite material can be obtained with deformation treatment using a high-pressure torsion (HPT) technique. The microstructure and mechanical properties of the HPT-processed material in different structural states were investigated. The HPT-processed material exhibits a high value of ultimate tensile strength (~770 MPa) but low ductility. Short-term annealing at 250 °C and additional deformation with HPT to 0.25 of revolution at room temperature resulted in a slight decrease in the material’s strength to ~700 MPa but provided ductility of ∼9%. Physical mechanisms to improve plasticity in correlation with microstructure evolution are discussed.
Comparative Study of the Relationship between Microstructure and Mechanical Properties of Aluminum Alloy 5056 Fabricated by Additive Manufacturing and Rolling Techniques Alexey Evstifeev, Darya Volosevich, Ivan Smirnov, Bulat Yakupov, Artem Voropaev, et al. Materials, 2023 In recent years, additive manufacturing of products made from 5000 series alloys has grown in popularity for marine and automotive applications. At the same time, little research has been aimed at determining the permissible load ranges and areas of application, especially in comparison with materials obtained by traditional methods. In this work, we compared the mechanical properties of aluminum alloy 5056 produced by wire-arc additive technology and rolling. Structural analysis of the material was carried out using EBSD and EDX. Tensile tests under quasi-static loading and impact toughness tests under impact loading were also carried out. SEM was used to examine the fracture surface of the materials during these tests. The mechanical properties of the materials under quasi-static loading conditions exhibit a striking similarity. Specifically, the yield stress σ0.2 was measured at 128 MPa for the industrially manufactured AA5056_IM and 111 MPa for the AA5056_AM. In contrast, impact toughness tests showed that AA5056_AM KCVfull was 190 kJ/m2, half that of AA5056_IM KCVfull, which was 395 kJ/m2.
Influence of Laser Beam Wobbling Parameters on Microstructure and Properties of 316L Stainless Steel Multi Passed Repaired Parts Artem Aleksandrovich Voropaev, Vladimir Georgievich Protsenko, Dmitriy Andreevich Anufriyev, Mikhail Valerievich Kuznetsov, Aleksey Alekseevich Mukhin, et al. Materials, 2022 The results of experimental studies of repair of the supporting structure components made of 316L steel multi-pass laser cladding with filler wire are presented. The influence of the wobbling mode parameters, welding speed, and laser power on the formation of the deposited metal during multi-pass laser cladding with filler wire of 316L steel samples into a narrow slot groove, 6 mm deep and 3 mm wide, are shown. Non-destructive testing, metallographic studies, and mechanical tests of the deposited metal before and after heat treatment (2 h at 450 °C) were carried out. Based on the results of experimental studies, the optimal modes of laser beam wobbling were selected (amplitude—1.3 mm, frequency—100 Hz) at which the formation of a bead of optimal dimensions (height—1672 μm, width—3939 μm, depth of penetration into the substrate—776 μm) was ensured. A laser cladding technology with ESAB OK Autrode 316L filler wire has been developed, which has successfully passed the certification for conformity with the ISO 15614-11 standard. Studies of the chemical elements’ distribution before and after heat treatment showed that, after heat treatment along the grain boundaries, particles with a significantly higher Mo content (5.50%) were found in the sample, presumably precipitated phases. Microstructure studies and microhardness measurements showed that the upper part metal of the third pass, which has a lower microhardness (75% of base metal), higher ferrite content, and differently oriented dendritic austenite, significantly differs from the rest of the cladded metal.
Features of filler wire melting and transferring in wire-arc additive manufacturing of metal workpieces Artem Voropaev, Rudolf Korsmik, Igor Tsibulskiy Materials, 2021 In this paper, we present the results of a study on droplet transferring with arc space short circuits during wire-arc additive manufacturing (WAAM GMAW). Experiments were conducted on cladding of single beads with variable welding current and voltage parameters. The obtained oscillograms and video recordings were analyzed in order to compare the time parameters of short circuit and arc burning, the average process peak current, as well as the droplets size. Following the experiments conducted, 2.5D objects were built-up to determine the influence of electrode stickout and welding torch travel speed to identify the droplet transferring and formation features. Moreover, the current–voltage characteristics of the arc were investigated with varying WAAM parameters. Process parameters have been determined that make it possible to increase the stability of the formation of the built-up walls, without the use of specialized equipment for forced droplet transfer. In the course of the research, the following conclusions were established: the most stable drop transfer occurs at an arc length of 1.1–1.2 mm, reverse polarity provides the best drop formation result, the stickout of the electrode wire affects the drop transfer process and the quality of the deposited layers. The dependence of the formation of beads on the number of short circuits per unit length is noted.
Application Development for the Evaluation of Penetration in Laser and Laser-Arc Hybrid Welding of Tee and Corner Joints Ilya Nikolaevich Udin, A.A. Voropaev, A. Unt Key Engineering Materials, 2019 Laser technologies deservedly take their place in modern mechanical engineering production. Using laser source for welding has already become common. However, the creation of critical welded constructions is impossible without extensive technological surveys, which can be greatly simplified by using a computational experiment. To achieve this goal, special programs are usually used. That can be unjustified difficult and thereby awkward for technological practice. The article describes an application built on the basis of a simplified model for calculating the temperature field for the cases of laser and laser-arc welding of internal fillet welds as well as single-sided T-joints and simultaneous double-sided welds. The results of calculations by the model and comparing them with experimental data have shown that it is sufficiently adequate for use in technological purposes. The developed application contemporaneously has a simple and intuitive interface, does not require significant computational resources and can be used for quick preliminary estimation of the result of welding for the selected type of weld.
Research of the structure defects at wire-feed laser and laser-arc deposition with almg6 A.A. Voropaev, A.D. Akhmetov, Thomas Hassel, George G. Klimov Key Engineering Materials, 2019 In comparison with other additive methods, the wire additive manufacturing has some advantages, chief among: high deposition rate and low price for consumables. Otherwise there are some disadvantages such as a high level of internal defects (hot, cold cracks, pores). Adding laser radiation to a WAAM process can significantly reduce data flaws. In this paper outlined research results on the effect of laser radiation (pulsed and permanent) on structure and internal defects of deposit layers to create three-component structures from AlMg6 alloy. Reported samples was made by using hybrid laser-arc method and by applying a single laser. Presented photos of macrosections of obtained samples. Spectral analysis was performed to identify the nature of changes of grains in different processes. Were made the measurements of internal defects and chemical analysis of the obtained walls.
