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<p>Wire arc additive manufacturing (WAAM) has emerged as a promising technique for producing large metallic components at reduced cost but the fabrication dissimilar metal structures remain challenging due to interfacial instability and compositional mismatch. In the present work, bimetallic wall consists of mild steel (MS) and stainless steel SS316L was successfully fabricated using gas metal arc welding (GMAW)-based WAAM process. The results demonstrate the formation of a sound metallurgical bond at the interface region without any visible defects. The MS region exhibited ferrite-pearlite microstructure, whereas the SS316L region showed austenitic structure with equiaxed and columnar grains formed under directional solidification. Localized Laves phase precipitates were observed in interdendritic regions of SS316L due to segregation of Nb and Mo. Electron backscatter diffraction suggested a smooth transition in grain morphology, with a predominance of medium to high-angle grain boundaries indicating stable metallurgical bonding across the interface region. The hardness profile showed a gradual increase from 203 HV in the MS region to 392 HV in the SS316L region, with an intermediate value of 264 HV at the interface region. Tensile results revealed that the SS316L region exhibited the highest strength with an ultimate tensile strength (UTS) of 541&#xa0;MPa and yield strength (YS) of 306&#xa0;MPa, while the MS region showed a UTS of 479&#xa0;MPa and YS of 272&#xa0;MPa. The bimetallic interface region revealed intermediate properties with a UTS of 498&#xa0;MPa and YS of 295&#xa0;MPa. Fracture consistently occurred in the MS region, indicating the superior mechanical integrity of the interface region. These results show that controlled WAAM processing can produce MS-SS316L bimetallic structures without visible defects while maintaining reliable mechanical properties suitable for industrial applications.</p>

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Wire arc additive manufacturing of MS-SS316L bimetallic structures: interfacial integrity and mechanical performance

  • 期刊论文

  • 发表日期：

    2026年7月14日

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  • Manish Singh,
  • Suresh Gain,
  • Surendra Singh,
  • Shiv Kumar Ray,
  • Tejendra Singh

摘要

Wire arc additive manufacturing (WAAM) has emerged as a promising technique for producing large metallic components at reduced cost but the fabrication dissimilar metal structures remain challenging due to interfacial instability and compositional mismatch. In the present work, bimetallic wall consists of mild steel (MS) and stainless steel SS316L was successfully fabricated using gas metal arc welding (GMAW)-based WAAM process. The results demonstrate the formation of a sound metallurgical bond at the interface region without any visible defects. The MS region exhibited ferrite-pearlite microstructure, whereas the SS316L region showed austenitic structure with equiaxed and columnar grains formed under directional solidification. Localized Laves phase precipitates were observed in interdendritic regions of SS316L due to segregation of Nb and Mo. Electron backscatter diffraction suggested a smooth transition in grain morphology, with a predominance of medium to high-angle grain boundaries indicating stable metallurgical bonding across the interface region. The hardness profile showed a gradual increase from 203 HV in the MS region to 392 HV in the SS316L region, with an intermediate value of 264 HV at the interface region. Tensile results revealed that the SS316L region exhibited the highest strength with an ultimate tensile strength (UTS) of 541 MPa and yield strength (YS) of 306 MPa, while the MS region showed a UTS of 479 MPa and YS of 272 MPa. The bimetallic interface region revealed intermediate properties with a UTS of 498 MPa and YS of 295 MPa. Fracture consistently occurred in the MS region, indicating the superior mechanical integrity of the interface region. These results show that controlled WAAM processing can produce MS-SS316L bimetallic structures without visible defects while maintaining reliable mechanical properties suitable for industrial applications.