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<p>The current study involved the manufacturing of a dissimilar alloy wall using Super duplex stainless steel 2507 (SDSS 2507) and nickel-based superalloy Inconel 718 (IN718) through the Cold Metal Transfer (CMT) based Wire Arc Directed Energy process. The wall generated by this procedure displayed a desirable structure. In addition, there was no evidence of solidification cracking in the interface (IF) region. The microstructural characteristics reveal a discontinuity in the dendritic structure and an abrupt transition at the IF. A confirmation of the fine disintegration of elements at the IF was found by energy-dispersive X-ray spectroscopy (EDS), and no significant change in composition was noted. Microstructure investigation indicates build-direction epitaxial grain growth and deposited layer non-equilibrium microstructures. SDSS 2507’s SEM microscopy displays austenite and ferrite in the lower part, and IN 718’s shows columnar and cellular crystals with white laves phases, which form when Nb and Mo elements segregate. The IF samples at a 90° angle in the SDSS 2507L region experienced failure due to a lower Ultimate Tensile Strength (UTS) than IN718. The fracture mode observed was ductile. The microhardness measurements illustrate the progressive variation in building direction hardness. The current study emphasizes the potential of the Wire Arc Directed Energy process in producing dissimilar alloy walls with desired properties. This technique is a feasible alternative to conventional manufacturing methods for creating dissimilar alloy structures.</p>

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Microstructure and Mechanical Characterization of Dissimilar Super Duplex Stainless Steel 2507–Inconel 718 Alloy Structure Built by Cold Metal Transfer-Based Wire Arc Directed Energy Deposition

  • 期刊论文

  • 发表日期：

    2025年8月18日

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  • Rajendra Prasad,
  • Narayan Yuvaraj,
  • Vipin

摘要

The current study involved the manufacturing of a dissimilar alloy wall using Super duplex stainless steel 2507 (SDSS 2507) and nickel-based superalloy Inconel 718 (IN718) through the Cold Metal Transfer (CMT) based Wire Arc Directed Energy process. The wall generated by this procedure displayed a desirable structure. In addition, there was no evidence of solidification cracking in the interface (IF) region. The microstructural characteristics reveal a discontinuity in the dendritic structure and an abrupt transition at the IF. A confirmation of the fine disintegration of elements at the IF was found by energy-dispersive X-ray spectroscopy (EDS), and no significant change in composition was noted. Microstructure investigation indicates build-direction epitaxial grain growth and deposited layer non-equilibrium microstructures. SDSS 2507’s SEM microscopy displays austenite and ferrite in the lower part, and IN 718’s shows columnar and cellular crystals with white laves phases, which form when Nb and Mo elements segregate. The IF samples at a 90° angle in the SDSS 2507L region experienced failure due to a lower Ultimate Tensile Strength (UTS) than IN718. The fracture mode observed was ductile. The microhardness measurements illustrate the progressive variation in building direction hardness. The current study emphasizes the potential of the Wire Arc Directed Energy process in producing dissimilar alloy walls with desired properties. This technique is a feasible alternative to conventional manufacturing methods for creating dissimilar alloy structures.