FEA-Guided development of Inconel 625 clad on mild steel using WAAM and their cavitation erosion resistance

In the current study, Inconel 625 clad has been developed on mild steel using Wire Arc Additive Manufacturing (WAAM), achieving uniform, defect-free clad with robust metallurgical bonds. Advanced microstructural analysis has confirmed the homogeneity and integrity of the clad, revealing fine primary dendritic arm spacing and predominantly equiaxed dendrites. Finite Element Analysis (FEA) has been employed to accurately predict temperature variations during the WAAM process, with peak temperatures approximating 1300 °C, ensuring optimal thermal management and minimal thermal stresses and distortions. Rigorous cavitation erosion tests, encompassing diverse parametric combinations of jet velocities, stand-off distances, and impingement angles, have demonstrated significantly enhanced erosion resistance and reduced mass loss in cladded specimens relative to uncladded samples. Post-erosion evaluations using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray Spectroscopy (EDS) have indicated a homogeneous distribution of essential alloying elements, including Nickel, Chromium, and Molybdenum, notwithstanding the presence of surface anomalies such as cracks and pores. The findings underscore the superior durability and resilience of Inconel 625 clad, positioning them as a viable solution for prolonging the operational lifespan of hydraulic machinery components exposed to severe cavitation erosion.