Remanufacturing of low-carbon steel components using WAAM: microstructural, mechanical, and parametric analysis

Abstract This research paper investigates the remanufacturing of low-carbon steel components using wire-arc additive manufacturing (WAAM), aiming to enhance resource efficiency and sustainability in various industries. The study focuses on repairing flat plate test coupons with a pre-fabricated trapezoidal groove using GMAW-WAAM. The microstructural characteristics and mechanical performance of the repaired samples are compared to the base material, and the influence of heat treatment on the repaired parts is also examined. Planned experiments and empirical modeling are performed to analyze the impact of WAAM process parameters on mechanical properties, establishing correlations between parameters and desired performance characteristics. The WAAM-repaired plate demonstrates higher tensile strength and hardness due to strong bonding, and finer grain structure, while annealing reduces tensile strength and hardness. Additionally, the WAAM-repaired annealed plate exhibits improved elongation compared to the WAAM-repaired plate but remains lower than the base plate. Observations revealed that the strength, elongation, and hardness of repaired samples are influenced by WAAM parameters in complex ways, with favorable combinations yielding improved properties.