Powder-infused arc cladding for enhanced mechanical and corrosion performance

This study investigates the influence of Inconel 625 and chromium (Cr) powders on the mechanical and corrosion performance of AM70 (8MnNiMoCrSi7-6-5) steel clads, produced via the arc-directed energy deposition process on AISI 1020 substrates. The surface properties of AM70 clads are enhanced with the addition of Inconel 625, a nickel superalloy, and chromium powders. Three clad compositions, AM70, AM70 with Inconel 625, and AM70 with Cr are tested and compared with each other and the substrate material. Results show that the GMAW (gas metal arc welding)-WAAM (wire arc additive manufacturing) produces dense, homogeneous cladding layers with smooth interfaces, ensuring strong bonding and defect-free fusion zones. The addition of Cr and Inconel 625 significantly improves microhardness through solid solution strengthening, with Cr+AM70 reaching 463.14 HV 0.5 , three times harder than the substrate. Corrosion evaluations reveal that IN625+AM70 exhibits the best performance, with minimal corrosion current density, the highest positive corrosion potential, and the greatest impedance modulus. These findings demonstrate that powder-infused GMAW-WAAM clads are promising for use in sectors such as aviation, automotive, and maritime.