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<p>This study demonstrates the feasibility of fabricating high-performance dissimilar metal structures (DMS) using wire arc additive manufacturing (WAAM) with SS304 and Inconel 601 filler wires. The fabricated DMS exhibited a refined microstructure with a combination of equiaxed and columnar dendrites, resulting in enhanced tensile strength (554.9&#xa0;MPa) and ductility (33.8 %), outperforming both individual SS304 and Inconel 601 counterparts. The simulated tensile results from finite element analysis closely matched the experimental data with less than 1 % error. Electron backscatter diffraction revealed a high fraction of low-angle grain boundaries contributing to improved mechanical performance. These findings establish the potential of WAAM for fabricating robust, corrosion-resistant DMS suitable for aerospace and energy application. This work is among the preliminary studies to experimentally and numerically validate the mechanical behavior of WAAM-fabricated SS304/Inconel 601 dissimilar structures with less than 1% simulation error with microstructural correlation.</p>

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Mechanical and Microstructural Evaluation of Wire Arc Additively Manufactured SS304/Inconel 601 Dissimilar Metal Structure: Insights from Experimental and Finite Element Analysis

  • 期刊论文

  • 发表日期：

    2025年9月30日

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  • Udhayakumar Kalappan,
  • Mohan Kumar Subramaniyan,
  • Dhinakaran Veeman,
  • Vijayakumar Murugesan Devarajan

摘要

This study demonstrates the feasibility of fabricating high-performance dissimilar metal structures (DMS) using wire arc additive manufacturing (WAAM) with SS304 and Inconel 601 filler wires. The fabricated DMS exhibited a refined microstructure with a combination of equiaxed and columnar dendrites, resulting in enhanced tensile strength (554.9 MPa) and ductility (33.8 %), outperforming both individual SS304 and Inconel 601 counterparts. The simulated tensile results from finite element analysis closely matched the experimental data with less than 1 % error. Electron backscatter diffraction revealed a high fraction of low-angle grain boundaries contributing to improved mechanical performance. These findings establish the potential of WAAM for fabricating robust, corrosion-resistant DMS suitable for aerospace and energy application. This work is among the preliminary studies to experimentally and numerically validate the mechanical behavior of WAAM-fabricated SS304/Inconel 601 dissimilar structures with less than 1% simulation error with microstructural correlation.