Please login first
Influence of Heat Input on Interface Properties in WAAM-Fabricated Steel-Based Aluminium, Inconel, and stainless-steel Bimetallic Structures
1, 2 , 3 , * 1, 2
1  CSIR-Central Mechanical Engineering Research Institute, Durgapur – 713209, West Bengal, India
2  Academy of Scientific and Innovative Research, Ghaziabad, 201002, Uttar Pradesh, India
3  Indian Institute of Technology (Indian School of Mines), Dhanbad, Jharkhand 826004, India
Academic Editor: Ingo Dierking

Abstract:

Fabricating bimetallic structures (BmSs) to reduce weight and improve performance has challenges in automobile, infrastructure, and aerospace applications. This study investigates the effect of heat input, QH, on interfacial properties of three different wire-arc additive manufacturing (WAAM)-based BmSs, SS316L-SS308L, EN31–AA4043, and SS316L–In718, through microstructural and mechanical characterisations. The value 250-400 J/mm is the determined heat input range for SS-SS and SS-Inconel, and for steel–aluminium, the range is 35-60 J/mm. At the interface of SS316L-SS308L BmS, both the austenitic (γ) and delta-ferrite (δ-Fe) phases formed. The higher tensile strength and elongation reached 591 MPa and 37.2 %, respectively, at an optimum QH of 330 J/mm, as the composition of the interface was close to the mirror composition with filler wire. While the average micro-hardness achieved at the interface is 248.3 HV, due to δ-α phases, the interface hardness is enhanced. But for the SS316L–In718 interface, the formation of IMCs (FeNi and FeNi₃) is proportionally influenced by the variation in QH. The SEM-EDX analysis demonstrated the enhancement of interface thickness (IT) and elongation while tensile stress was reduced (optimum: 542 MPa) with increasing QH. The average micro-hardness value reduced (194.7 to 174.6 HV) with increasing QH due to the coarse grain structure. Conversely, the optimum QH was achieved at 43.55 J/mm for the EN31-Al4043 interface, and the SEM and XRD analyses revealed the brittle binary (Fe-Al) and ternary (Al-Fe-Si) IMC formations at the interface. Under optimal conditions, minimal IT (<4 µm), considerable tensile strength (73.2 MPa), very little elongation (~0.9%), and an average micro-hardness value of 128.1 HV were achieved. This analysis highlights heat input as a crucial factor for developing tailored BmSs using WAAM as it controls interface properties. To develop a multi-material high-performance structure, process parameters should be optimized.

Keywords: Wire Arc Additive Manufacturing (WAAM); Bimetallic Structures (BmSs); Heat Input Optimization; Intermetallic Compounds (IMCs); Interface Characterization.
Top