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<p>Predicting the mechanical response of additively manufactured bimetal structures remains challenging due to heterogeneous microstructures and nonlinear deformation. This study explores a novel wire-based additive manufacturing (WAAM)-fabricated bimetallic wall of Inconel 825 (IN825) and stainless steel 304 (SS304), aimed at load-bearing structural applications. Tensile testing combined with the modified Ramberg–Osgood (RO) model accurately captured the nonlinear stress–strain behavior, achieving high <i>R</i><sup>2</sup> values (0.92 for the bimetallic wall, 0.97 for IN825, and 0.96 for SS304). The bimetallic wall exhibited enhanced mechanical performance with a yield strength of 302&#xa0;MPa, a tensile strength of 563&#xa0;MPa, and a higher strain-hardening exponent (8.08), demonstrating superior plastic deformation resistance over the base metals. The findings establish that WAAM could produce high-performance bimetallic structures, and the RO model provides a strong predictive tool for their mechanical behavior.</p>

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Understanding the Relationship Between Microstructural Features and Stress–Strain Behavior of Wire-Based Additively Manufactured Bimetal Structure

  • 期刊论文

  • 发表日期：

    2025年11月5日

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  • Dhamodharan Balaji,
  • Vijayakumar Murugesan Devarajan,
  • Dhinakaran Veeman,
  • Mohan Kumar Subramaniyan

摘要

Predicting the mechanical response of additively manufactured bimetal structures remains challenging due to heterogeneous microstructures and nonlinear deformation. This study explores a novel wire-based additive manufacturing (WAAM)-fabricated bimetallic wall of Inconel 825 (IN825) and stainless steel 304 (SS304), aimed at load-bearing structural applications. Tensile testing combined with the modified Ramberg–Osgood (RO) model accurately captured the nonlinear stress–strain behavior, achieving high R2 values (0.92 for the bimetallic wall, 0.97 for IN825, and 0.96 for SS304). The bimetallic wall exhibited enhanced mechanical performance with a yield strength of 302 MPa, a tensile strength of 563 MPa, and a higher strain-hardening exponent (8.08), demonstrating superior plastic deformation resistance over the base metals. The findings establish that WAAM could produce high-performance bimetallic structures, and the RO model provides a strong predictive tool for their mechanical behavior.