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<p>Conventional dissimilar welding joints with maintained structural integrity remains a significant challenge in the fabrication of multi-material engineering components. This study investigates fabrication of a seamless dissimilar stainless steel structure (DSSS) through Wire Arc Additive Manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) process. A defect-free DSSS was successfully manufactured by sequentially depositing SS316L and SS308L, thereby eliminating the need for conventional joining techniques and associated weld interfaces. Macrostructural examination confirmed the absence of visible defects, such as cracks, porosity, and lack of fusion, while microstructural characterization revealed sound metallurgical bonding with a continuous transition across the dissimilar interface. Mechanical evaluation demonstrated that the seamless DSSS achieved a tensile strength of 605.1 ± 5&#xa0;MPa, which was higher than WA-SS316L (491.31 ± 10&#xa0;MPa) and comparable to WA-SS308L (615.7 ± 12&#xa0;MPa), indicating effective load transfer across the dissimilar region. Furthermore, finite element analysis (FEA) was performed to predict the tensile behavior of the fabricated structure. The numerical predictions showed excellent agreement with experimental results, with deviations of less than 1% for all tested specimens, validating the reliability of the developed model. The combined experimental and numerical findings demonstrate the capability of WAAM-GMAW to produce seamless dissimilar stainless steel structures with robust metallurgical integrity and superior mechanical performance for advanced engineering application.</p>

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Macro-Microstructure, Mechanical Properties, and Numerical Analysis of Seamless Dissimilar Stainless Steel Structure Produced by Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • Dhinakaran Veeman,
  • S. G. Channabasavanna,
  • Micheal Agnelo Browne,
  • Sanjay Kannan,
  • Mohith Mohan Das,
  • Mohan Kumar Subramaniyan

摘要

Conventional dissimilar welding joints with maintained structural integrity remains a significant challenge in the fabrication of multi-material engineering components. This study investigates fabrication of a seamless dissimilar stainless steel structure (DSSS) through Wire Arc Additive Manufacturing (WAAM) using Gas Metal Arc Welding (GMAW) process. A defect-free DSSS was successfully manufactured by sequentially depositing SS316L and SS308L, thereby eliminating the need for conventional joining techniques and associated weld interfaces. Macrostructural examination confirmed the absence of visible defects, such as cracks, porosity, and lack of fusion, while microstructural characterization revealed sound metallurgical bonding with a continuous transition across the dissimilar interface. Mechanical evaluation demonstrated that the seamless DSSS achieved a tensile strength of 605.1 ± 5 MPa, which was higher than WA-SS316L (491.31 ± 10 MPa) and comparable to WA-SS308L (615.7 ± 12 MPa), indicating effective load transfer across the dissimilar region. Furthermore, finite element analysis (FEA) was performed to predict the tensile behavior of the fabricated structure. The numerical predictions showed excellent agreement with experimental results, with deviations of less than 1% for all tested specimens, validating the reliability of the developed model. The combined experimental and numerical findings demonstrate the capability of WAAM-GMAW to produce seamless dissimilar stainless steel structures with robust metallurgical integrity and superior mechanical performance for advanced engineering application.