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<p>This study investigates the influence of two wire arc additive manufacturing (WAAM) configurations, namely Cold Metal Transfer (CMT) and Dual-Metal Inert Gas (Dual-MIG), on the microstructural evolution, corrosion behavior, and mechanical performance of AISI 308LSi/ER70S-6 functionally graded materials. The fabricated walls were characterized by optical microscopy, X-ray diffraction, energy-dispersive spectroscopy, electrochemical corrosion testing, microhardness measurements, and tensile testing. Both deposition processes successfully produced metallurgically bonded functionally graded walls with similar phase constituents. However, significant differences were observed in the compositional gradient and interfacial microstructure. The CMT process produced a sharper compositional transition, a narrower dilution zone, finer pearlitic microstructures, and a narrower martensitic interfacial layer, resulting in higher mechanical strength than the Dual-MIG (YS: 324 vs. 236&#xa0;MPa; UTS: 427 vs. 391&#xa0;MPa). In contrast, the different thermal characteristics of Dual-MIG process promoted enhanced elemental diffusion, greater δ-ferrite retention, and a wider martensitic transition zone, leading to improved corrosion resistance and greater ductility (22.4% vs. 17%). In both configurations, peak microhardness (&gt; 400 HV) was localized at the interface owing to martensite formation, while tensile failure consistently occurred in the ER70S-6 region. These findings demonstrate that the selection of the WAAM deposition configuration provides an effective approach to tailor the interfacial microstructure, thereby improving the corrosion resistance and mechanical performance of steel-based functionally graded materials according to application requirements.</p>

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AISI 308LSi/ER70S-6 dissimilar steel functionally graded materials fabricated by cold metal transfer and dual-metal inert gas wire arc additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年7月18日

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  • Mohamed Ziane Boutebina,
  • Brahim Mehdi,
  • Khawla Amara,
  • Riad Badji

摘要

This study investigates the influence of two wire arc additive manufacturing (WAAM) configurations, namely Cold Metal Transfer (CMT) and Dual-Metal Inert Gas (Dual-MIG), on the microstructural evolution, corrosion behavior, and mechanical performance of AISI 308LSi/ER70S-6 functionally graded materials. The fabricated walls were characterized by optical microscopy, X-ray diffraction, energy-dispersive spectroscopy, electrochemical corrosion testing, microhardness measurements, and tensile testing. Both deposition processes successfully produced metallurgically bonded functionally graded walls with similar phase constituents. However, significant differences were observed in the compositional gradient and interfacial microstructure. The CMT process produced a sharper compositional transition, a narrower dilution zone, finer pearlitic microstructures, and a narrower martensitic interfacial layer, resulting in higher mechanical strength than the Dual-MIG (YS: 324 vs. 236 MPa; UTS: 427 vs. 391 MPa). In contrast, the different thermal characteristics of Dual-MIG process promoted enhanced elemental diffusion, greater δ-ferrite retention, and a wider martensitic transition zone, leading to improved corrosion resistance and greater ductility (22.4% vs. 17%). In both configurations, peak microhardness (> 400 HV) was localized at the interface owing to martensite formation, while tensile failure consistently occurred in the ER70S-6 region. These findings demonstrate that the selection of the WAAM deposition configuration provides an effective approach to tailor the interfacial microstructure, thereby improving the corrosion resistance and mechanical performance of steel-based functionally graded materials according to application requirements.