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<p>Cold metal transfer (CMT) is an efficient wire arc process for protective surface cladding. Nickel–copper superalloys exhibit exceptional strength and corrosion resistance, making them suitable for demanding marine applications. However, their high material costs often necessitate economic alternatives. In this study, Monel 400 was cladded over a stainless steel (SS) 304 substrate using a CMT clad technique. Clad parameters and offset were selected through systematic experiments. Microstructural, mechanical, and corrosion testing were performed to assess the quality of the clad. A sharp interface with minimal dilution was observed, ensuring structural integrity. The Monel 400 clad region showed a columnar dendritic structure, while the SS 304 substrate showed an equiaxed morphology. Microhardness decreased from both ends toward the interface, with a hardness spike at the interface due to dilution of substrate. Tensile tests revealed that the Monel 400 clad has superior mechanical properties, followed by the interfacial and substrate region (SS 304). Electrochemical corrosion studies demonstrated that Monel 400 clads have superior corrosion resistance, followed by the interface and substrate region. Electrochemical studies demonstrated superior corrosion resistance of Monel 400 clad (corrosion rate: 0.0158&#xa0;mm/year) compared to interface (0.0315&#xa0;mm/year) and substrate (0.0678&#xa0;mm/year). Monel 400 cladding provided effective corrosion protection with stable passive film formation, while SS 304 substrate showed susceptibility to localized corrosion in chloride environment. The interface region exhibited intermediate tensile strength and corrosion resistance as a result of the synergistic effect between Monel 400 and SS 304. The Monel 400 cladding effectively shielded the SS 304 substrate from pitting while contributing to enhanced mechanical strength and surface hardness.</p>

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Microstructural, Mechanical, and Corrosion Behavior of Monel 400 Cladding on Stainless Steel 304 via Cold Metal Transfer

  • 期刊论文

  • 发表日期：

    2026年2月10日

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  • Lalit Kumar Yadav,
  • Adarsh Kumar,
  • Abhishek Anand,
  • Joy Prakash Misra,
  • Rajnesh Tyagi

摘要

Cold metal transfer (CMT) is an efficient wire arc process for protective surface cladding. Nickel–copper superalloys exhibit exceptional strength and corrosion resistance, making them suitable for demanding marine applications. However, their high material costs often necessitate economic alternatives. In this study, Monel 400 was cladded over a stainless steel (SS) 304 substrate using a CMT clad technique. Clad parameters and offset were selected through systematic experiments. Microstructural, mechanical, and corrosion testing were performed to assess the quality of the clad. A sharp interface with minimal dilution was observed, ensuring structural integrity. The Monel 400 clad region showed a columnar dendritic structure, while the SS 304 substrate showed an equiaxed morphology. Microhardness decreased from both ends toward the interface, with a hardness spike at the interface due to dilution of substrate. Tensile tests revealed that the Monel 400 clad has superior mechanical properties, followed by the interfacial and substrate region (SS 304). Electrochemical corrosion studies demonstrated that Monel 400 clads have superior corrosion resistance, followed by the interface and substrate region. Electrochemical studies demonstrated superior corrosion resistance of Monel 400 clad (corrosion rate: 0.0158 mm/year) compared to interface (0.0315 mm/year) and substrate (0.0678 mm/year). Monel 400 cladding provided effective corrosion protection with stable passive film formation, while SS 304 substrate showed susceptibility to localized corrosion in chloride environment. The interface region exhibited intermediate tensile strength and corrosion resistance as a result of the synergistic effect between Monel 400 and SS 304. The Monel 400 cladding effectively shielded the SS 304 substrate from pitting while contributing to enhanced mechanical strength and surface hardness.