Processing, mechanical performance, and corrosion behavior of AM70 steel clads with martensitic steel powders on low-carbon steel using WAAM

Abstract This study investigates the surface cladding of AISI 1020 low-carbon steel using the arc-DED (direct energy deposition) process with Rockit ® 431SR martensitic stainless-steel powder and AM 70 feedstock wire. The powder is overlaid onto the substrate surface and fused by the heat generated during the MIG (metal inert gas)-WAAM (wire arc additive manufacturing) process using AM 70 wire, forming a clad layer. The study evaluates the microhardness distribution, phase composition, residual stress, and electrochemical corrosion behavior of the Rockit ® 431SR + AM 70 clad, comparing it with the AISI 1020 substrate and AM 70-clad AISI 1020 without powder addition. The results show that the Rockit ® 431SR + AM 70 cladding significantly improves microhardness and corrosion resistance, making it a promising solution for industries requiring high wear and corrosion resistance. The findings include superior microhardness in the clad layers, compressive residual stress, and enhanced electrochemical properties, including higher corrosion potential and improved pitting resistance. It has been found that Rockit ® 431SR + AM 70 cladding offers enhanced durability and corrosion resistance compared to AM 70-clad AISI 1020 and the AISI 1020 substrate, enhancing its applicability across the automotive, marine, and infrastructure sectors.