Mechanical Properties of Dispersion-Strengthened Iron-Based W+WC(Ni) Composite Produced by Combined Wire Electron-Beam Manufacturing with Powder Addition

The paper investigates the microstructure and mechanical properties of a steel matrix composite reinforced with tungsten (W) particles and a mixture of tungsten carbide and nickel (WC(Ni)) obtained by a hybrid additive manufacturing method using wire electron beam additive manufacturing with powder addition. The composite exhibits a gradient structure including three zones: a matrix of high alloy steel 401S45, a transition layer with a low concentration of W/WC(Ni) and a surface layer enriched with particles of reinforcing phases. SEM, TEM and XRD methods revealed a heterogeneous microstructure consisting of α-Fe (80 vol.%), γ-Fe (10 vol.%) and carbide phases, as well as suppression of the formation of brittle Me3C intermetallides due to the controlled diffusion of W, C and alloying elements. The microhardness of the composite increases from 350 HV (matrix) to 650 HV (reinforced layer) due to dispersion hardening and formation of the carbide skeleton. Compression tests showed record strength of the reinforced layer (1720 ± 60 MPa) due to effective load distribution by W/WC(Ni) particles, but brittle failure is observed in tensile tests due to stress concentration at the interfaces.