Evaluation of Mechanical Properties and Microstructure of High-Strength Steel Walls Fabricated by Wire ARC Additive Manufacturing
1
Faculty of Mechanical Engineering, Le Quy Don Technical University, Viet Nam
2
Advanced Technology Center, Le Quy Don Technical University, Viet Nam
3
Faculty of Mechanical Engineering and Mechatronics, PHENIKAA University, Viet Nam
4
Faculty of Vehicle & Energy Engineering, PHENIKAA University, Viet Nam
5
Institute of sustainable manufacturing, University of Kentucky, United States
Submission date: 2026-03-12
Final revision date: 2026-03-29
Acceptance date: 2026-03-30
Online publication date: 2026-04-16
Corresponding author
Van Tuan Nguyen
Faculty of Mechanical Engineering and Mechatronics, PHENIKAA University, Hanoi, Viet Nam
Faculty of Mechanical Engineering and Mechatronics, PHENIKAA University, Hanoi, Viet Nam
KEYWORDS
TOPICS
ABSTRACT
This study investigates the microstructural and mechanical characteristics of a high-strength steel thin wall fabricated via wire arc additive manufacturing (WAAM). A 20-layer wall was produced using a bidirectional deposition strategy with fixed processing parameters to ensure repeatability. Microstructural analysis revealed significant spatial heterogeneity along the build direction. The bottom region exhibited the finest grain size (0.96±0.23 μm) due to the substrate heat sink effect, while the top region reveals the coarsest grain size (1.84±0.36 μm) due to slower cooling rates. XRD analysis confirmed the deposited material consists entirely of the ferrite phase. Mechanical testing showed a microhardness gradient ranging from 256±17.04 HV0.1 at the top to 288±16.78 HV0.1 at the bottom that directly correlates with grain refinement. Tensile tests revealed exceptional performance with ultimate tensile strength (UTS) exceeding 980 MPa, yield strength (YS0.2%) in range of 560–620 MPa, and elongation above 20%, meeting industrial requirements for structural applications. Fracture surface morphology confirmed a ductile micro-void coalescence mechanism, indicating high plastic deformation capability. These results demonstrate the WAAM capability to produce high-strength, structurally reliable steel components, supporting its application in large-scale manufacturing for shipbuilding, heavy engineering, and load-bearing structural systems.
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| eISSN: | 2391-8071 |
| ISSN: | 1895-7595 |
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