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<p>This research focuses on a hybrid additive manufacturing method that combines Powder Bed Fusion (PBF) and Wire Arc Additive Manufacturing (WAAM) to construct a bimaterial system of Maraging Steel 1 substrate and Inconel 625 deposition. The hybrid specimen exhibited favorable mechanical performance, with an ultimate tensile strength of 1128 ± 28&#xa0;MPa, a yield strength of 983 ± 22&#xa0;MPa, and a hardness gradient from 482&#xa0;HV in the Maraging Steel region to 248&#xa0;HV in the Inconel 625 region. A peak hardness of 538&#xa0;HV was observed at the interface due to refined grains and intermetallic phase formation. FESEM analysis revealed fine lath martensite in PBF regions and coarse columnar dendrites with segregation in WAAM layers. EBSD confirmed epitaxial grain growth, high-angle grain boundaries, and local strain accumulation at the interface, contributing to strain localization and reduced ductility. The results confirm the metallurgical compatibility and performance capabilities of the hybrid PBF-WAAM process, highlighting the critical role of interface engineering in ensuring structural reliability.</p>

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Mechanical and Microstructural Analysis of Hybrid Additive Manufacturing of Maraging Steel 1 and Inconel 625 via Powder Bed Fusion and Wire Arc Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年3月10日

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  • P. Balakumar,
  • V. Senthilkumar,
  • M. Kumaran

摘要

This research focuses on a hybrid additive manufacturing method that combines Powder Bed Fusion (PBF) and Wire Arc Additive Manufacturing (WAAM) to construct a bimaterial system of Maraging Steel 1 substrate and Inconel 625 deposition. The hybrid specimen exhibited favorable mechanical performance, with an ultimate tensile strength of 1128 ± 28 MPa, a yield strength of 983 ± 22 MPa, and a hardness gradient from 482 HV in the Maraging Steel region to 248 HV in the Inconel 625 region. A peak hardness of 538 HV was observed at the interface due to refined grains and intermetallic phase formation. FESEM analysis revealed fine lath martensite in PBF regions and coarse columnar dendrites with segregation in WAAM layers. EBSD confirmed epitaxial grain growth, high-angle grain boundaries, and local strain accumulation at the interface, contributing to strain localization and reduced ductility. The results confirm the metallurgical compatibility and performance capabilities of the hybrid PBF-WAAM process, highlighting the critical role of interface engineering in ensuring structural reliability.