Influence of Graphene‐Based Flux Interlayers on the Microstructure and Properties of Low‐Alloy Steel Fabricated by Cold Metal Transfer‐Based Wire Arc Additive Manufacturing

This study investigates the impact of graphitic flux interlayers on the material characteristics of low-carbon steel produced via cold metal transfer-based wire arc additive manufacturing (CMT-WAAM). Specifically, multi-layered graphene (MLG) powder was incorporated as an interlayer flux between successive deposited layers, creating a GR-IL specimen, which was then systematically compared against a standard ER70S6 specimen fabricated without such an interlayer. The research encompassed a comprehensive evaluation of microstructural features, mechanical properties, tribological behavior, and corrosion resistance. Findings indicate that the MLG interlayer significantly enhanced the deposition process, leading to notable grain refinement, with grain size decreasing from 12 to 8 µm. Concurrently, the pearlite content increased from 39.79% to 45.15%,

signifying an alteration in phase transformation kinetics. This microstructural modification contributed to an improvement in hardness, rising from 178 to 184 HV, thereby enhancing resistance to plastic deformation. Tensile testing revealed anisotropic mechanical responses, with comparable ultimate tensile strength in horizontal and diagonal orientations, while the vertical orientation exhibited reduced strength. Furthermore, pin-on-disc tribological assessments demonstrated superior wear resistance for the GR-IL specimen, evidenced by a reduced specific wear rate of 2.0 × 10 −6 mm 3 /N·m, compared to 4.5 × 10 −6 mm 3 /N·m for the ER70S6 counterpart. The study underscores the potential of graphene-based interlayers in optimizing the functional performance of additively manufactured steel components.

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