Investigation of Microstructure, Hardness, and Wear Behavior of Hardfacing Produced by Wire Laser Additive Manufacturing

Wire Laser Additive Manufacturing (WLAM) has emerged as a promising alternative for the fabrication and repair of components subjected to severe wear conditions due to its high deposition rate, efficient material utilization, and localized thermal control. In this study, the WLAM process using DUR600 wire as the feedstock material for the deposition of abrasion-resistant coatings was investigated. The deposited specimens were characterized by optical emission spectroscopy (OES), X-ray diffraction (XRD), optical microscopy (OM), scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM/EDS), Vickers microhardness testing, and dry sand/rubber wheel abrasion testing in accordance with ASTM G65. The deposits exhibited a predominantly martensitic microstructure with retained austenite, as confirmed by XRD. Hardness values ranged from 749 to 817 HV, with an average of 783 ± 18 HV, while the average volumetric loss in the abrasive wear test was 150.26 mm3. This behavior was attributed to the presence of the martensitic matrix and retained austenite, whose combined effect directly influences the tribological performance of WLAM coatings produced using DUR600 wire.