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<p>This study aims at the fabrication and analysis of bi-metallic structures (BMSs) using wire arc additive manufacturing (WAAM) with SS 308L and SS 304 material toward enabling their mechanical properties and microstructural integrity improvement for some critical industrial applications. These studies have used a customized WAAM setup and a combination of experimental methods and finite element simulation techniques to explore tensile behavior in the fabricated BMS walls. Process parameters, including heat energy input, deposition rate, and layer orientation, were optimized to produce defect-free structures. Experimental results showed a remarkable improvement in tensile strength, where the WAAM-processed BMS outperformed its wrought alloy counterparts, and a tensile strength error of less than 1% between experimental and simulated data. Microstructural analyses revealed columnar and equiaxed grain structures, including low-angle grain boundaries (LAGBs), contributing to increased strength. The research shows the promising potential of WAAM in producing strong and high-performance materials with the minimum requirement of extensive physical testing. This work underlines the importance of microstructural optimization and provides a pathway for broader adoption of WAAM in industries such as aerospace, marine, and energy.</p>

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Experimental and Finite Element Simulation of Bi-Metallic Structure Processed through Wire Arc Additive Manufacturing: A Behavioral Study

  • 期刊论文

  • 发表日期：

    2025年8月7日

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  • Murugan Vellaisamy,
  • Pradeep Castro,
  • Dhinakaran Veeman,
  • Mohan Kumar Subramaniyan,
  • Micheal Angelo Browne,
  • Sanjay Kannan,
  • Tharun Kumar Muthu Kumar,
  • Sarankumar Thanigainathan

摘要

This study aims at the fabrication and analysis of bi-metallic structures (BMSs) using wire arc additive manufacturing (WAAM) with SS 308L and SS 304 material toward enabling their mechanical properties and microstructural integrity improvement for some critical industrial applications. These studies have used a customized WAAM setup and a combination of experimental methods and finite element simulation techniques to explore tensile behavior in the fabricated BMS walls. Process parameters, including heat energy input, deposition rate, and layer orientation, were optimized to produce defect-free structures. Experimental results showed a remarkable improvement in tensile strength, where the WAAM-processed BMS outperformed its wrought alloy counterparts, and a tensile strength error of less than 1% between experimental and simulated data. Microstructural analyses revealed columnar and equiaxed grain structures, including low-angle grain boundaries (LAGBs), contributing to increased strength. The research shows the promising potential of WAAM in producing strong and high-performance materials with the minimum requirement of extensive physical testing. This work underlines the importance of microstructural optimization and provides a pathway for broader adoption of WAAM in industries such as aerospace, marine, and energy.