Mechanical and Microstructure analysis of ER410 stainless steel processed by wire arc additive manufacturing (WAAM)

Wire Arc Additive Manufacturing (WAAM) is promising technique for producing large scale metallic components due to its high deposition rate, cost efficiency, and suitability for complex geometry. This study investigates the Cold Metal Transfer (CMT)-based Wire Arc Additive Manufacturing (WAAM) process for ER410 martensitic stainless steel, with a focus on the fundamental effects of process parameters. Single layer deposition was first conduct to evaluate the influence of travel speed on bead geometry, with optimal parameters identified at 95A current, 3.0 m/min wire feed speed, 10.8V voltage, and 2.75 mm/s travel speed. The optimal parameters produced bead heigh of 5.12 mm and width of 3.44 mm. Using these parameters, multilayer wall was fabricated and characterized. Microstructural analysis revealed predominant martensitic features with localized crack like indications increasing toward the top layers due to repeated thermal cycle. Hardness values reached up to 400 HV near the fusion line, attributed to grain refinement. Mechanical testing demonstrated anisotropy, with vertical specimen exhibited higher tensile strength average of 1116.25 MPa compare to 853.92 MPa for horizontal specimens. These finding provide essential baseline knowledge for WAAM processing of ER410 stainless steel and highlight its potential for manufacturing high strength.