RSM investigation of dry abrasion in WAAM fabricated inconel 625 cladding on EN8 steel

This study investigates the microstructural evolution, mechanical behavior, and abrasive wear resistance of EN8 steel cladded with varying proportions of vanadium carbide (VC) reinforced Inconel 625. A comparative analysis among specimens uncladded base (EN8), In1, In15VC, and In25VC demonstrates the progressive enhancement in microhardness and bond strength with increasing VC content, achieving a maximum of 568 ± 19 HV and 135 ± 7 N, respectively, in In25VC. Microstructural observations reveal the formation of elongated dendrites and cellular crystals, contributing to robust metallurgical bonding and improved mechanical integrity. Abrasive wear testing, including dry rubber wheel and pin-on-disc methods, shows that In25VC exhibits the lowest mass loss, attributed to the high hardness and strategic distribution of VC particles that hinder abrasive penetration. Statistical analysis using response surface methodology (RSM) and ANOVA confirms the significant influence of process parameters such as load, particle size, and sand flow rate on wear behavior. Optimization using numerical desirability functions yields a high predictive correlation with experimental data, validating model accuracy. SEM investigations further delineate distinct wear mechanisms across cladded and uncladded specimens, highlighting the role of VC in minimizing micro-cutting, groove formation, and pit propagation. Overall, the integration of 25% VC into Inconel 625 matrix clads substantially enhances wear resistance, positioning it as a promising strategy for extending the durability of steel components in abrasive environments.