Published Paper Details:

Inconel 625 is widely used in aerospace, marine, and chemical industries owing to its exceptional corrosion resistance and high-temperature strength; however, its poor machinability and moderate wear resistance limit broader structural applications. Wire and arc additive manufacturing (WAAM) offer a cost-effective route for fabricating large-scale Inconel 625 components but tailoring their surface and bulk properties through in-situ reinforcement remains underexplored. This study addresses this gap by incorporating Titanium Carbide (TiC) particles (1-4 wt.%) into the melt pool using a dedicated powder feeder during vertical WAAM deposition, enabling uniform reinforcement without disrupting the process. The effect of TiC addition on hardness, tensile behavior, impact toughness, and wear resistance was systematically investigated. Hardness increased steadily with reinforcement, reaching 342.8 HV at 4 wt.% TiC (~22% higher than the base alloy), while ultimate tensile strength improved by 8-12%, with a peak value of 712.8 MPa for 3 wt.% TiC. Pin-on-disc tests under 1- 3 kg loads showed up to ~32% reduction in cumulative wear loss compared to the unreinforced alloy, confirming the role of TiC in enhancing surface durability. However, impact toughness decreased by 15-56% with increasing TiC content, indicating a trade-off between strengthening and ductility. These findings demonstrate that in-process TiC reinforcement during WAAM provides a robust pathway to simultaneously improve mechanical performance and wear resistance of Inconel 625, expanding its applicability in demanding engineering environments.