Effect of Shielding Gases on the Microstructure and Mechanical Properties of Wire Arc Additively Manufactured Nickel Based Superalloy

Effect of Shielding Gases on the Microstructure and Mechanical Properties of Wire Arc Additively Manufactured Nickel Based Superalloy | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Effect of Shielding Gases on the Microstructure and Mechanical Properties of Wire Arc Additively Manufactured Nickel Based Superalloy Aishwary Mishra, Chakravarthy Pammi, Susarla Venkata Surya Narayana Murty This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-5890051/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 04 Jul, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Wire Arc Additive Manufacturing of Haynes 230 superalloy was systematically investigated to elucidate the profound influence of shielding gas compositions on microstructural evolution, mechanical properties and bead geometry. Employing pure Argon, pure Helium, and an Argon-Helium mixture under consistent deposition parameters, this study comprehensively examined the intricate relationships between shielding gas environments and material characteristics. Helium-based shielding demonstrated superior performance, producing broader and thinner beads with reduced profile waviness compared to Argon and Argon-Helium mixtures. Notably, pure Argon as shielding revealed critical inter-bead fusion limitations in the initial layer, potentially compromising structural integrity. Tensile testing substantiated Helium's effectiveness, with specimens exhibiting enhanced mechanical properties and superior microstructural homogeneity. Fractographic analysis revealed a predominantly ductile failure mechanism across all shielding gas configurations. Microstructural investigations consistently identified W-Cr rich carbides, representing a significant transformation from the feedstock's primary W-rich carbide structure. These findings underscore Helium's potential as an optimal shielding gas for precision manufacturing, while acknowledging Argon's advantages in cost-effective and expedited production processes. The research provides critical insights into the nuanced interactions between shielding gases and additive manufacturing parameters, offering valuable guidance for advanced materials processing strategies in high-performance superalloy fabrication. Additive Manufacturing Wire Arc Additive Manufacturing Superalloy Lack of Fusion Shielding Gases Full Text Cite Share Download PDF Status: Published Journal Publication published 04 Jul, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 26 Apr, 2025 Reviewers agreed at journal 20 Mar, 2025 Reviewers invited by journal 19 Mar, 2025 Editor assigned by journal 28 Jan, 2025 First submitted to journal 27 Jan, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-5890051","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":431301451,"identity":"6f122f19-f697-45af-8a3d-f055f452625e","order_by":0,"name":"Aishwary Mishra","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Aishwary","middleName":"","lastName":"Mishra","suffix":""},{"id":431301452,"identity":"f2d017c0-fb39-4925-aec5-1b748b039542","order_by":1,"name":"Chakravarthy Pammi","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA9UlEQVRIiWNgGAWjYDACCQZmKIuHgeGDgQSUY0CMFjYeBsYZQC08JGlh5oFYhh/wz25+bFxRc1jefH7vMWmbAgt7ewbmhx8YCu7gtuTOMePEM8cOG845xpcmnWMgkdjDwGYswWDwDKcWA4kE44MNbGmMM9h4zEBaEoAOMwOKH8ajJf3zwYZ/afZgLRYGEvY8DOzfCGjJMU5sbLNJBGsBchl7GHjw2yJxI6fYsLHPJnkGW46xZQ/IL4d5iiUS8Gjhn5G+WbLhm4TtDOYzhjd+/KmzZ29v3/jhwx/cWpABCyTqQfGUQJQGoNoPRCocBaNgFIyCEQYAU3ZE93k3648AAAAASUVORK5CYII=","orcid":"","institution":"Indian Institute of Space Science and Technology","correspondingAuthor":true,"prefix":"","firstName":"Chakravarthy","middleName":"","lastName":"Pammi","suffix":""},{"id":431301453,"identity":"bcad802f-0b18-4fca-85db-4cd81ac41bfd","order_by":2,"name":"Susarla Venkata Surya Narayana Murty","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Susarla","middleName":"Venkata Surya Narayana","lastName":"Murty","suffix":""}],"badges":[],"createdAt":"2025-01-23 16:57:35","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-5890051/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-5890051/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-16023-7","type":"published","date":"2025-07-04T15:58:55+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":86180051,"identity":"30a7be46-05a7-4069-ab21-3531482f7f73","added_by":"auto","created_at":"2025-07-07 16:21:04","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":3051511,"visible":true,"origin":"","legend":"","description":"","filename":"1737976038719ManuscriptforsubmissionR8.pdf","url":"https://assets-eu.researchsquare.com/files/rs-5890051/v1_covered_380b4a4a-e4ac-4d3d-92f7-d89ee950acdb.pdf"}],"financialInterests":"","formattedTitle":"Effect of Shielding Gases on the Microstructure and Mechanical Properties of Wire Arc Additively Manufactured Nickel Based Superalloy","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":true,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Additive Manufacturing, Wire Arc Additive Manufacturing, Superalloy, Lack of Fusion, Shielding Gases","lastPublishedDoi":"10.21203/rs.3.rs-5890051/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-5890051/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"Wire Arc Additive Manufacturing of Haynes 230 superalloy was systematically investigated to elucidate the profound influence of shielding gas compositions on microstructural evolution, mechanical properties and bead geometry. 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These findings underscore Helium's potential as an optimal shielding gas for precision manufacturing, while acknowledging Argon's advantages in cost-effective and expedited production processes. 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