Weldability Evaluation for Alloy Design and Wire Arc Additive Manufacturing of Functionally Graded Materials for Harsh Service Environments

Weldability Evaluation for Alloy Design and Wire Arc Additive Manufacturing of Functionally Graded Materials for Harsh Service Environments | 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 Weldability Evaluation for Alloy Design and Wire Arc Additive Manufacturing of Functionally Graded Materials for Harsh Service Environments Giacomo S. Melaragno, Boian T. Alexandrov This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7973952/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract This study sought to evaluate the solidification cracking susceptibility in filler metals designed for wire arc additive manufacturing (WAAM) of a functionally graded pipe component for the harsh service conditions in olefin furnaces. Three filler metals corresponding to the outer diameter (OD), inner diameter (ID), and bulk (Core) regions of the tubular cross-section were developed based on previous computational design work. Cast pin tear testing (CPTT) was performed in this study to rank the solidification crack susceptibility among the three filler metals. CPTT samples were subsequently characterized by scanning electron microscopy (SEM) to propose potential mechanisms for the differences in crack susceptibility observed between the filler metals. Large, blocky Cr-rich carbides forming during solidification were identified as potential bad actors for solidification cracking susceptibility. The nature/amount of liquid ahead of the formation of these carbides was proposed to play a critical role in the difference in crack susceptibility observed among the three filler metals. Functionally Graded Materials Additive Manufacturing Cast Pin Tear Test Solidification Cracking High Temperature Figures Figure 1 Figure 2 Figure 6 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Full Text Cite Share Download PDF Status: Under Review Version 1 posted Reviewers agreed at journal 04 Nov, 2025 Reviewers invited by journal 03 Nov, 2025 Editor invited by journal 03 Nov, 2025 Editor assigned by journal 30 Oct, 2025 First submitted to journal 29 Oct, 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. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. 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-7973952","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":539129754,"identity":"45b65aff-8cf0-41c8-967d-6c64804aef57","order_by":0,"name":"Giacomo S. 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1","display":"","copyAsset":false,"role":"figure","size":939344,"visible":true,"origin":"","legend":"\u003cp\u003e(a) CPTT experimental setup in OSU laboratory, (b) CPTT sample in mold showing stress concentration and typical area where cracking is observed, (c) example of open crack, and (d) example of healed crack; red arrows indicate direction of restraint during CPTT\u003c/p\u003e","description":"","filename":"1.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/ecabeb58b63aba72c6a412b9.png"},{"id":96239985,"identity":"7b4f8fb8-8957-4dfb-8571-a8e8be19c34a","added_by":"auto","created_at":"2025-11-19 07:08:05","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":104004,"visible":true,"origin":"","legend":"\u003cp\u003eCPTT results plotting maximum circumferential cracking measured at each pin length tested for each of the three filler metals\u003c/p\u003e","description":"","filename":"2.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/d8355820da9b1f5ec0a5fce7.png"},{"id":96239599,"identity":"cd6cf5d8-7291-411a-b248-a90a4932289e","added_by":"auto","created_at":"2025-11-19 07:07:06","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":590151,"visible":true,"origin":"","legend":"\u003cp\u003ea) Fracture surface of fully separated 35/45 CPTT sample, (b) fracture surface facets that contain flat, blocky features, (c) fracture surface facets with liquid/dendritic appearance, (d) higher magnification image of inset area in (c)\u003c/p\u003e","description":"","filename":"6.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/875fa6b5abc6b6c0f7d9b080.png"},{"id":96239445,"identity":"53695f02-2e8c-4930-94a4-839c7d4be508","added_by":"auto","created_at":"2025-11-19 07:06:39","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":484573,"visible":true,"origin":"","legend":"\u003cp\u003e(a) Cross-section of 35/45-Al CPTT sample with 41% circumferential cracking and corresponding Cr-K EDS map for the inset region in the red box, (b) higher magnification view of features inside the crack tip from the inset area in the white box from (a) and corresponding EDS elemental maps; green arrows identify examples of NbC and orange arrows identify examples of NiAl\u003c/p\u003e","description":"","filename":"10.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/a41f3b7b87403f84add8af10.png"},{"id":96239468,"identity":"8d5a8c5e-f815-4c8b-b745-b1851d4cdcc2","added_by":"auto","created_at":"2025-11-19 07:06:44","extension":"png","order_by":11,"title":"Figure 11","display":"","copyAsset":false,"role":"figure","size":502130,"visible":true,"origin":"","legend":"\u003cp\u003eCross-section of 35/45-Al CPTT sample with 41% circumferential cracking with inset area to show (b) a dendritic feature witnessed from the cracked surface; (c) a high magnification image of the dendrite surface and corresponding EDS elemental maps; green arrows identify prismatic NbC and orange arrows identify examples of droplet-like Cr-carbides\u003c/p\u003e","description":"","filename":"11.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/d9471f369803eba218e54ab6.png"},{"id":96239570,"identity":"2733b53e-7f13-461a-b3c4-72f7cf2c0c95","added_by":"auto","created_at":"2025-11-19 07:06:59","extension":"png","order_by":12,"title":"Figure 12","display":"","copyAsset":false,"role":"figure","size":544617,"visible":true,"origin":"","legend":"\u003cp\u003e(a) Fracture surface for 35/45-Al CPTT sample with 30% circumferential cracking pulled to failure, (b) area of fracture surface where solidification cracking occurred during CPTT, (c) high magnification view of features in solidification fracture surface and corresponding EDS maps; green arrows identify examples of NbC\u003c/p\u003e","description":"","filename":"12.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/b37c81a2b97e7938cbba3370.png"},{"id":96239555,"identity":"680139b5-725d-4c94-b13b-d28e5da52012","added_by":"auto","created_at":"2025-11-19 07:06:57","extension":"png","order_by":13,"title":"Figure 13","display":"","copyAsset":false,"role":"figure","size":329931,"visible":true,"origin":"","legend":"\u003cp\u003eHigher magnification view of area between large NbC particles in Fig. 12c with corresponding EDS elemental maps; orange arrows point out droplet-like Cr-carbides sitting atop NbC substrates (dashed outlines)\u003c/p\u003e","description":"","filename":"13.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/93e76ff60ca82e367b1e22cf.png"},{"id":96239438,"identity":"b658c843-e2fa-4a6b-9252-699e29114818","added_by":"auto","created_at":"2025-11-19 07:06:39","extension":"png","order_by":14,"title":"Figure 14","display":"","copyAsset":false,"role":"figure","size":110203,"visible":true,"origin":"","legend":"\u003cp\u003eSolidification schematic with proposed timing of Cr-carbide formation/cracking in (a) 35/45, (b) 35/45-Si, and (c) 35/45-Al filler metals\u003cem\u003e.\u003c/em\u003e\u003c/p\u003e","description":"","filename":"14.png","url":"https://assets-eu.researchsquare.com/files/rs-7973952/v1/f01b643321dfd87169d717b8.png"}],"financialInterests":"","formattedTitle":"Weldability Evaluation for Alloy Design and Wire Arc Additive Manufacturing of Functionally Graded Materials for Harsh Service Environments","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":true,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Functionally Graded Materials, Additive Manufacturing, Cast Pin Tear Test, Solidification Cracking, High Temperature","lastPublishedDoi":"10.21203/rs.3.rs-7973952/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7973952/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study sought to evaluate the solidification cracking susceptibility in filler metals designed for wire arc additive manufacturing (WAAM) of a functionally graded pipe component for the harsh service conditions in olefin furnaces. Three filler metals corresponding to the outer diameter (OD), inner diameter (ID), and bulk (Core) regions of the tubular cross-section were developed based on previous computational design work. Cast pin tear testing (CPTT) was performed in this study to rank the solidification crack susceptibility among the three filler metals. CPTT samples were subsequently characterized by scanning electron microscopy (SEM) to propose potential mechanisms for the differences in crack susceptibility observed between the filler metals. Large, blocky Cr-rich carbides forming during solidification were identified as potential bad actors for solidification cracking susceptibility. The nature/amount of liquid ahead of the formation of these carbides was proposed to play a critical role in the difference in crack susceptibility observed among the three filler metals.\u003c/p\u003e","manuscriptTitle":"Weldability Evaluation for Alloy Design and Wire Arc Additive Manufacturing of Functionally Graded Materials for Harsh Service Environments","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-11-13 12:58:24","doi":"10.21203/rs.3.rs-7973952/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"reviewerAgreed","content":"","date":"2025-11-04T10:20:23+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-11-03T10:53:46+00:00","index":"","fulltext":""},{"type":"editorInvited","content":"Welding in the World","date":"2025-11-03T09:44:21+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-10-30T04:14:12+00:00","index":"","fulltext":""},{"type":"submitted","content":"Welding in the World","date":"2025-10-29T10:09:20+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"welding-in-the-world","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"witw","sideBox":"Learn more about [Welding in the World](https://www.springer.com/journal/40194)","snPcode":"40194","submissionUrl":"https://www.editorialmanager.com/witw/","title":"Welding in the World","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"891cdce4-e06c-47d2-baee-77801a230782","owner":[],"postedDate":"November 13th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"under-review","subjectAreas":[],"tags":[],"updatedAt":"2026-01-15T10:48:53+00:00","versionOfRecord":[],"versionCreatedAt":"2025-11-13 12:58:24","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7973952","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7973952","identity":"rs-7973952","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}