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<p>Reliable prediction of deformation behavior in multi-material components is essential for designing load-bearing structures in aerospace, marine, and nuclear sectors, where stainless steels are widely employed due to their strength and corrosion resistance. This study aims to enhance the understanding of elastic–plastic deformation in dissimilar stainless steel structures fabricated via wire arc additive manufacturing (WAAM), a process offering cost-effective production of large metallic parts. A bimetallic wall consisting of SS316L and SS308L was deposited and examined to assess its microstructural and mechanical response. Microstructural characterization and ferrite number are evaluated. The dissimilar wall exhibited a yield strength of 335&#xa0;MPa, ultimate tensile strength of 605&#xa0;MPa, and elongation of 29%. The true stress–strain behavior was modeled using the Ramberg–Osgood (RO) equation, showing a strong correlation (<i>R</i><sup>2</sup> = 0.9244 for the dissimilar structure) and a strain-hardening exponent of 8.4. Fractographic analysis confirmed ductile fracture with uniformly distributed dimples and localized strain near the interface. Overall, the study establishes a predictive framework combining microstructural analysis, experimental testing, and analytical modeling for evaluating and optimizing the mechanical integrity of multi-material WAAM-fabricated components for advanced structural application.</p>

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Stress–Strain Representation of Additively Manufactured Dissimilar Metal Structure Using Ramberg–Osgood Equation: Testing and Microstructural Features

  • 期刊论文

  • 发表日期：

    2025年11月11日

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  • Dhinakaran Veeman,
  • Kanishkaa Jeevaraj,
  • Mohith Mohan Das,
  • Pechimuthu Arumugaperumal,
  • Micheal Agnelo Browne,
  • Mohan Kumar Subramaniyan

摘要

Reliable prediction of deformation behavior in multi-material components is essential for designing load-bearing structures in aerospace, marine, and nuclear sectors, where stainless steels are widely employed due to their strength and corrosion resistance. This study aims to enhance the understanding of elastic–plastic deformation in dissimilar stainless steel structures fabricated via wire arc additive manufacturing (WAAM), a process offering cost-effective production of large metallic parts. A bimetallic wall consisting of SS316L and SS308L was deposited and examined to assess its microstructural and mechanical response. Microstructural characterization and ferrite number are evaluated. The dissimilar wall exhibited a yield strength of 335 MPa, ultimate tensile strength of 605 MPa, and elongation of 29%. The true stress–strain behavior was modeled using the Ramberg–Osgood (RO) equation, showing a strong correlation (R2 = 0.9244 for the dissimilar structure) and a strain-hardening exponent of 8.4. Fractographic analysis confirmed ductile fracture with uniformly distributed dimples and localized strain near the interface. Overall, the study establishes a predictive framework combining microstructural analysis, experimental testing, and analytical modeling for evaluating and optimizing the mechanical integrity of multi-material WAAM-fabricated components for advanced structural application.