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<p>The increasing demand for high-performance, cost-effective materials has accelerated the exploration of multi-material additive manufacturing (AM) solutions. In this study, we introduce a novel framework for bi-metallic wire arc additive manufacturing (WAAM), focusing on the deposition of dissimilar metal pairs—specifically high-performance alloy IN718 and low-carbon steel (LCS). This approach enables the fabrication of intricate components with optimized, application-specific properties. The developed framework integrates tailored deposition processes, an innovative deposition selection number method for parameter optimization, and advanced deposition strategies, enabling the production of a defect-free IN718-LCS bi-metallic structure. Shear testing reveals an average interfacial shear strength of 403&#xa0;MPa, which exceeds the&#xa0;American Society for Testing and Materials (ASTM)-A265-12 standard. The mechanical integrity is bolstered by a robust interlocking mechanism, with fracture surfaces displaying a balanced combination of ductile and cleavage modes, and no observable cracks or defects. Microhardness analysis confirmed a seamless transition at the interface, free from brittle intermetallic phases, reinforcing the joint’s structural integrity. This research provides critical insights into the design and manufacturing of reliable bi-metallic structures, underscoring the transformative potential of WAAM in advanced material applications.</p>

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Strategies for enhanced interfacial strength in IN718-LCS bi-metallic structure fabricated using wire arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年3月27日

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  • Angshuman Kapil,
  • Abhishek G. Narasimhan,
  • Seyed Aref Banaee,
  • Joachim Antonissen,
  • Abhay Sharma

摘要

The increasing demand for high-performance, cost-effective materials has accelerated the exploration of multi-material additive manufacturing (AM) solutions. In this study, we introduce a novel framework for bi-metallic wire arc additive manufacturing (WAAM), focusing on the deposition of dissimilar metal pairs—specifically high-performance alloy IN718 and low-carbon steel (LCS). This approach enables the fabrication of intricate components with optimized, application-specific properties. The developed framework integrates tailored deposition processes, an innovative deposition selection number method for parameter optimization, and advanced deposition strategies, enabling the production of a defect-free IN718-LCS bi-metallic structure. Shear testing reveals an average interfacial shear strength of 403 MPa, which exceeds the American Society for Testing and Materials (ASTM)-A265-12 standard. The mechanical integrity is bolstered by a robust interlocking mechanism, with fracture surfaces displaying a balanced combination of ductile and cleavage modes, and no observable cracks or defects. Microhardness analysis confirmed a seamless transition at the interface, free from brittle intermetallic phases, reinforcing the joint’s structural integrity. This research provides critical insights into the design and manufacturing of reliable bi-metallic structures, underscoring the transformative potential of WAAM in advanced material applications.