Development of DED Process Parameters for Deposition of Bronze and Evaluation of Its Wear Properties under Dry Sliding Conditions

With the Directed Energy Deposition (DED) process, we aim to develop an efficient way to reduce the use of bronze in worm gears. Due to the limited study conducted on the DED of bronze on steel substrate, optimizing the process parameters for a high-quality deposition is essential. Therefore, in the current study, we evaluate the effect of process parameters such as laser power, feed rate, and scanning speed on the deposition of Bronze on a 42CrMo4V substrate. Single bronze tracks were deposited using different laser power values, feed rates, and scanning speed. Cross-sections of the depositions were analyzed for porosity and track dimensions to obtain the aspect ratio. The best parameters from the single-track deposition were selected, and multiple-layer deposition was created for a thickness of 3 mm. Cylindrical specimens were extracted from this multilayer deposition and subjected to wear tests using the pin-on-disc configuration under dry sliding conditions against a 42CrMo4V counterface to check for debonding and friction behavior. The DED specimens were characterized for porosity, microstructure, and microhardness. Finally, the results, when compared with the properties of wrought Bronze, indicate that the DED bronze can be used as a replacement for wrought Bronze in gears.