Abstract A bimetallic additively-manufactured structure (BAMS) is a type of functionally-graded multi-material structure used for achieving different complementary material properties within the same structure as well as cost optimization. Wire + arc additive manufacturing (WAAM) offers the capability to fabricate the BAMS in a simultaneous or sequential way. To fully utilize the benefits of the BAMS, the interfacial joint should be strong, and each of the constituents should have reasonable mechanical integrity. For this, a BAMS of low-carbon steel and austenitic-stainless steel was fabricated using a gas-metal-arc-welding (GMAW)-based WAAM process. Then, the BAMS was heat-treated at a range of 800 °C to 1,100 °C and 30 minutes to 2 hours. This resulted in 35% and 250% increases in the ultimate tensile strength and elongation, compared to the as-deposited BAMS. After the heat-treatment, the failure location moved from the low-carbon-steel to the stainless-steel side. Scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDAx), and the Vickers hardness test were used to characterize the BAMS. In this paper, it is experimentally validated that heat-treatment at 950 °C-1 hour is the near-optimal condition for the BAMS.
Wire + arc additive manufacturing (WAAM) uses existing welding technology to make a part from metal deposited in an almost net shape. WAAM is flexible in that it can use multiple materials successively or simultaneously during the manufacturing of a single component.,In this work, a gas metal arc welding (GMAW) based wire + arc additive manufacturing (WAAM) system has been developed to use two material successively and fabricate bimetallic additively manufactured structure (BAMS) of low carbon s...
#1A. N. M. Tanvir(Tennessee Technological University)H-Index: 4
#2Md. R. U. Ahsan(Tennessee Technological University)H-Index: 5
Last. Duck Bong Kim(Tennessee Technological University)H-Index: 11
view all 6 authors...
Wire + arc additive manufacturing (WAAM) is a versatile, low-cost, energy-efficient technology used in metal additive manufacturing. This WAAM process uses arc welding to melt a wire and form a three-dimensional (3D) object using a layer-by-layer stacking mechanism. In the present study, a Ni-based superalloy wire, i.e., Inconel 625, is melted and deposited additively through a cold metal transfer (CMT)-based WAAM process. The deposited specimens were heat-treated at 980 °C (the recommended temp...
Abstract To benefit from the fascinating properties of multi-material structures, the interfacial joint should exhibit good mechanical strength. Evaluating the shear strength of a bimetallic joint via conventional methods is usually complex, and in most cases produces unreliable data due to induced bending stress among others. In this work, a novel single-shear test device was designed and fabricated to measure shear strength of bimetallic joints. The device was first standardized by shearing st...
ABSTRACTFunctionally graded components are usually preferred for severe and critical service conditions, thanks to the possibility of achieving different complementary material properties within the same structure. Wire + Arc Additive Manufacturing is an emerging technology which lends itself well to the production of sound graded structures. In this study, an integral structure of two functional gradients, namely tantalum to molybdenum, and molybdenum to tungsten, was successfully deposited. A ...
#1J.S. Zuback(PSU: Pennsylvania State University)H-Index: 9
#2Todd Palmer(PSU: Pennsylvania State University)H-Index: 31
Last. Tarasankar Debroy(PSU: Pennsylvania State University)H-Index: 78
view all 3 authors...
Abstract Dissimilar metal joints between ferritic and austenitic alloys are susceptible to premature failure due to diffusive carbon loss from the ferritic alloy driven by abrupt changes in carbon chemical potential. Compositional grading of transition joints fabricated using laser-based directed energy deposition additive manufacturing offers a means for limiting carbon diffusion. Here we fabricate functionally graded transition joints between a ferritic and austenitic alloy, characterize spati...
Purpose The purpose of this study is to conduct gas tungsten arc dissimilar welding of AISI 304 stainless steel and low carbon steel within a process window so as to investigate the effects of current, speed and gas flow rate (GFR) on the microstructure and mechanical properties of the weldments. Design/methodology/approach The welding experiment was carried out at different combinations of parameters using WN-250S Kaierda electric welding machine. A combination of scanning electron microscopy a...
Abstract Bimetallic structures belong to a class of multi-material structures, and they potentially offer unique solutions to many engineering problems. In this work, bimetallic structures of Inconel 718 and Ti6Al4V (Ti64) alloys were processed using laser engineered net shaping (LENS™). During LENS™ processing, three build strategies were attempted: direct deposition, compositional gradation and use of an intermediate bond layer. Inconel 718 and Ti64 alloys exhibit thermal properties mismatch a...
The present study is to investigate the effect of post heat treatment on the microstructures and mechanical properties of a submerged-arc-welded 304 stainless steel. The base material consisted of austenite and long strips of delta-ferrite surrounded by Cr-carbide, and the welds consisted of delta ferrite and austenite matrix. For the heat treatment at 850 °C or lower, Cr-carbides were precipitated in the weld metal resulting in the reduction of elongation. The strength, however, was slightly re...
Abstract The austenitic stainless steel 316L was fabricated by gas metal arc additive manufacturing (GMA-AM) and its microstructure and room temperature tensile properties were investigated. Results show that in the GMA-AM 316L plate, a large number of well-aligned austenitic dendrites vertically orient, forming large columnar grains in the middle and some dendrites bent toward the plate surfaces, forming small columnar grains near the edges. The microstructure of GMA-AM 316L consists of δ, γ an...
Abstract null null null This article presents the Laser Beam Direct Energy Deposition (DED-LB) process as a method to build a graded austenitic-to-martensitic steel junction. null Builds were obtained by varying the ratio of the two powders during DED-LB processing. Samples with gradual transitions were successfully obtained using a high dilution rate from one layer to the next. Long austenitic grains are observed on the 316 L side while martensitic grains are observed on the Fe–9Cr–1Mo side. In...
Last. Duck Bong Kim(Tennessee Technological University)H-Index: 11
view all 7 authors...
Abstract null null The goal of this study is to investigate the wire + arc additive manufacturing (WAAM) of a high-entropy alloy (HEA) and to identify the near-optimal process parameters. To achieve the goal, a two-stage investigation is attempted using pre-alloyed and extruded Al0.1CoCrFeNi wire. In the first stage, single-layer beads are deposited with a range of process parameters (current, wire feed speed, and travel speed). Through process-signal monitoring, bead cross-section measurements,...
#1Laukik P. Raut(VRCE: Visvesvaraya National Institute of Technology)
#2Ravindra V. Taiwade(VRCE: Visvesvaraya National Institute of Technology)H-Index: 14
Over the past years, the demand for the wire arc additive manufacturing (WAAM) is potentially increased, and it has become a promising alternative to subtractive manufacturing. Research reported that the wire arc additively manufactured (WAAMed) material’s mechanical properties are comparable to wrought or cast material. In comparison with other fusion sources, WAAM offers a significant cost saving and a higher deposition rate. However, there are significant challenges associated with WAAM such ...
#2Susanta Kumar Sahoo(NITR: National Institute of Technology, Rourkela)H-Index: 14
Abstract Additive manufacturing (AM) route is a promising approach for fabricating complex and lightweight metallic structures that have applications in various sectors such as automotive, aerospace, and biomedical industries. Laser, electron beam, and electric arc are the common power sources available for AM. Out of different metal AM techniques, wire-feed additive manufacturing has been considered as a promising alternative for fabricating metallic parts for various applications. As it provid...
#1S. Mohan Kumar(National Institute of Technology, Tiruchirappalli)H-Index: 4
#2A. Rajesh Kannan(National Institute of Technology, Tiruchirappalli)H-Index: 5
Last. S.G. Channabasavanna(Maharaja Institute of Technology, Coimbatore)H-Index: 1
view all 7 authors...
The additively fabricated functionally gradient structures can be a potential replacement for conventionally manufactured structures via fusion welding techniques. A SS321/Inconel 625 functionally gradient material was processed by wire arc additive manufacturing (WAAM) process. The WAAM-formed SS321 comprises of equiaxed and columnar structures, while the Inconel 625 consists of dendritic structures. It can be concluded that a very narrow interface was formed between the additively manufactured...
Metal additive manufacturing technologies, such as powder bed fusion process, directed energy deposition (DED) process, sheet lamination process, etc., are one of promising flexible manufacturing technologies due to direct fabrication characteristics of a metallic freeform with a three-dimensional shape from computer aided design data. DED processes can create an arbitrary shape on even and uneven substrates through line-by-line deposition of a metallic material. Theses DED processes can easily ...
Bimetallic structures offer properties that can be customized based on applications, manufactured in one operation. Such manufacturing options are fascinating, as joining two metallic materials, especially for two dissimilar metals without significant defects, is challenging. In this study, 316L stainless steel (SS) to Al12Si aluminum alloy structures were processed, tailoring the compositionally graded interface on a SS 316 substrate using a directed energy deposition (DED)-based additive manuf...
Due to the complexity of and variations in additive manufacturing (AM) processes, there is a level of uncertainty that creates critical issues in quality assurance (QA), which must be addressed by time-consuming and cost-intensive tasks. This deteriorates the process repeatability, reliability and part reproducibility. So far, many AM efforts have been performed in an isolated and scattered way over several decades. In this paper, a systematically integrated holistic view is proposed to achieve ...
#1A. Rajesh Kannan(National Institute of Technology, Tiruchirappalli)H-Index: 5
#2S. Mohan Kumar(National Institute of Technology, Tiruchirappalli)H-Index: 4
Last. Yasam Palguna(IITH: Indian Institute of Technology, Hyderabad)H-Index: 2
view all 6 authors...
Wire arc additive manufacturing (WAAM) with better material utilisation efficiency and higher deposition rate was employed to fabricate bi-metallic structure (BMS) of non-stabilised austenitic stai...