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<p>Accurately modeling tensile behavior of dissimilar metal structures fabricated via Wire Arc Additive Manufacturing (WAAM) remains challenging due to compositional gradients and anisotropic deformation. In this study, a modified Ramberg–Osgood (RO) model is developed and validated for predicting the nonlinear stress–strain behavior of a WAAM-fabricated dissimilar metal stainless steel 304 (SS304)-Inconel 625 (IN625) wall. The additively built wall exhibited a yield strength of 392&#xa0;MPa, ultimate tensile strength of 599&#xa0;MPa, and elongation of 36%, demonstrating superior strength compared to monolithic SS304 while maintaining comparable ductility to IN625. The modified RO formulation effectively captured the elastic–plastic transition with high accuracy (<i>R</i><sup>2</sup> = 0.93-0.96), confirming its reliability for dissimilar AM structures. The higher strain-hardening exponent (n = 12.23) of the bimetallic wall is observed than its counterparts due to variation in the <i>δ</i>-ferrite content. Microstructural and fractographic examinations revealed sound metallurgical bonding, epitaxial grain growth, and ductile fracture with failure initiating near the SS304 region. The proposed model offers a simplified yet accurate framework for describing deformation in dissimilar WAAM builds. These findings establish the mechanical reliability and predictive modeling potential of multi-material WAAM components for aerospace, marine, and energy application.</p>

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Stress–Strain Plots for Fabricated Dissimilar Metal Additive Walls by Ramberg–Osgood Equation

  • 期刊论文

  • 发表日期：

    2026年4月2日

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  • Madhankumar Ganesan,
  • Vijayakumar Murugesan Devarajan,
  • Dhinakaran Veeman,
  • Mohan Kumar Subramaniyan

摘要

Accurately modeling tensile behavior of dissimilar metal structures fabricated via Wire Arc Additive Manufacturing (WAAM) remains challenging due to compositional gradients and anisotropic deformation. In this study, a modified Ramberg–Osgood (RO) model is developed and validated for predicting the nonlinear stress–strain behavior of a WAAM-fabricated dissimilar metal stainless steel 304 (SS304)-Inconel 625 (IN625) wall. The additively built wall exhibited a yield strength of 392 MPa, ultimate tensile strength of 599 MPa, and elongation of 36%, demonstrating superior strength compared to monolithic SS304 while maintaining comparable ductility to IN625. The modified RO formulation effectively captured the elastic–plastic transition with high accuracy (R2 = 0.93-0.96), confirming its reliability for dissimilar AM structures. The higher strain-hardening exponent (n = 12.23) of the bimetallic wall is observed than its counterparts due to variation in the δ-ferrite content. Microstructural and fractographic examinations revealed sound metallurgical bonding, epitaxial grain growth, and ductile fracture with failure initiating near the SS304 region. The proposed model offers a simplified yet accurate framework for describing deformation in dissimilar WAAM builds. These findings establish the mechanical reliability and predictive modeling potential of multi-material WAAM components for aerospace, marine, and energy application.