Tailoring Surface Properties of Low‐Carbon Steel Through Graphene and Inconel 718‐Reinforced Cladding via Wire Arc Additive Method

Surface degradation of low‐carbon steel remains a major concern in engineering applications under severe conditions. Wire arc additive manufacturing (WAAM) provides an economical approach for localized surface modification through cladding. In this study, low‐carbon steel was surface‐modified using single‐layer WAAM cladding with graphene nanoplatelets (GNPs) and Inconel 718 reinforcement. Microstructural examination revealed grain refinement in the clad surface compared to the substrate metal. Graphene reinforcement increased the formation of acicular ferrite, while IN718 reinforcement produced an equiaxed dendritic structure. Mechanical characterization revealed a progressive enhancement in hardness by the introduction of graphene and IN718 in the clad layer. The graphene‐reinforced clad surface showed an average surface hardness of 177.8 HV 0.2 , while the IN718‐reinforced clad surface reached 322.1 HV 0.2 . Tensile results showed an increase in UTS with a reduction in elongation for the graphene‐reinforced clad; meanwhile, the IN718 clad exhibited a brittle nature, resulting in lower UTS and significantly reduced elongation. Dry sliding wear tests showed reduced wear rates for all surface‐modified samples, especially the IN718‐reinforced clad surface, which exhibited a much lower wear rate than the base metal. The findings demonstrate that reinforced WAAM cladding is an effective large‐area surface engineering strategy for improving hardness and wear resistance of low‐carbon steel.