Investigating stainless steel/aluminum bimetallic structures fabricated by cold metal transfer (CMT)-based wire-arc directed energy deposition

Md Abdul Karim; Sainand Jadhav; Rangasayee Kannan; Dean Pierce; Yousub Lee; Peeyush Nandwana; Duck Bong Kim

doi:10.1016/j.addma.2024.104015

Investigating stainless steel/aluminum bimetallic structures fabricated by cold metal transfer (CMT)-based wire-arc directed energy deposition

Md Abdul Karim, Sainand Jadhav, Rangasayee Kannan, Dean Pierce, Yousub Lee, Peeyush Nandwana, Duck Bong Kim

Research output: Contribution to journal › Article › peer-review

8 Scopus citations

Abstract

This study investigated the process of fabricating a bimetallic structure of 316L stainless steel (SS) and 4043 aluminum (Al) using wire-arc directed energy deposition (DED) based on the cold metal transfer (CMT) process. The impact of heat input on the fabricated structure's geometry, porosity, and microstructures at the interface, with a specific emphasis on the intermetallic compound (IMC) formation, and the subsequent impact on the joint strength of the structure, were studied. The IMC layer at the interface was predominantly comprised of FeAl₂Si. For the various heat input conditions studied, the IMC layer's thickness varied from 5 µm to 18 µm. The tensile strength reached up to approximately 130 MPa, which is among the highest reported in the literature for steel/Al bimetallic structures. The specimens fabricated with high heat input conditions had a thicker IMC layer at the steel/Al interface, resulting in a more brittle interface and degradation of the mechanical properties.

Original language	English
Article number	104015
Journal	Additive Manufacturing
Volume	81
DOIs	https://doi.org/10.1016/j.addma.2024.104015
State	Published - Feb 5 2024

Funding

This research is sponsored by the Laboratory Directed Research and Development Program of Oak Ridge National Laboratory, managed by UT-Battelle, LLC, for the US Department of Energy. Research was performed at the U.S. Department of Energy’s Manufacturing Demonstration Facility, located at Oak Ridge National Laboratory. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05–00OR22725 with the U.S. Department of Energy. The authors acknowledge Dustin Heidel and Ian Stinson for arc melting and machining, Cody Taylor for mechanical testing, and Sarah Graham for metallographic sample preparation. Notice: This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). Notice: This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy ( DOE ). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-public-access-plan ).

Funders	Funder number
DOE Public Access Plan
U.S. Department of Energy	DE-AC05–00OR22725
Oak Ridge National Laboratory

Keywords

Bimetallic structure
Bonding strength
Cold metal transfer
Intermetallic compound
Wire-arc directed energy deposition

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10.1016/j.addma.2024.104015

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title = "Investigating stainless steel/aluminum bimetallic structures fabricated by cold metal transfer (CMT)-based wire-arc directed energy deposition",

abstract = "This study investigated the process of fabricating a bimetallic structure of 316L stainless steel (SS) and 4043 aluminum (Al) using wire-arc directed energy deposition (DED) based on the cold metal transfer (CMT) process. The impact of heat input on the fabricated structure's geometry, porosity, and microstructures at the interface, with a specific emphasis on the intermetallic compound (IMC) formation, and the subsequent impact on the joint strength of the structure, were studied. The IMC layer at the interface was predominantly comprised of FeAl2Si. For the various heat input conditions studied, the IMC layer's thickness varied from 5 µm to 18 µm. The tensile strength reached up to approximately 130 MPa, which is among the highest reported in the literature for steel/Al bimetallic structures. The specimens fabricated with high heat input conditions had a thicker IMC layer at the steel/Al interface, resulting in a more brittle interface and degradation of the mechanical properties.",

keywords = "Bimetallic structure, Bonding strength, Cold metal transfer, Intermetallic compound, Wire-arc directed energy deposition",

author = "Karim, {Md Abdul} and Sainand Jadhav and Rangasayee Kannan and Dean Pierce and Yousub Lee and Peeyush Nandwana and Kim, {Duck Bong}",

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AU - Kannan, Rangasayee

AU - Pierce, Dean

AU - Lee, Yousub

AU - Nandwana, Peeyush

AU - Kim, Duck Bong

PY - 2024/2/5

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N2 - This study investigated the process of fabricating a bimetallic structure of 316L stainless steel (SS) and 4043 aluminum (Al) using wire-arc directed energy deposition (DED) based on the cold metal transfer (CMT) process. The impact of heat input on the fabricated structure's geometry, porosity, and microstructures at the interface, with a specific emphasis on the intermetallic compound (IMC) formation, and the subsequent impact on the joint strength of the structure, were studied. The IMC layer at the interface was predominantly comprised of FeAl2Si. For the various heat input conditions studied, the IMC layer's thickness varied from 5 µm to 18 µm. The tensile strength reached up to approximately 130 MPa, which is among the highest reported in the literature for steel/Al bimetallic structures. The specimens fabricated with high heat input conditions had a thicker IMC layer at the steel/Al interface, resulting in a more brittle interface and degradation of the mechanical properties.

AB - This study investigated the process of fabricating a bimetallic structure of 316L stainless steel (SS) and 4043 aluminum (Al) using wire-arc directed energy deposition (DED) based on the cold metal transfer (CMT) process. The impact of heat input on the fabricated structure's geometry, porosity, and microstructures at the interface, with a specific emphasis on the intermetallic compound (IMC) formation, and the subsequent impact on the joint strength of the structure, were studied. The IMC layer at the interface was predominantly comprised of FeAl2Si. For the various heat input conditions studied, the IMC layer's thickness varied from 5 µm to 18 µm. The tensile strength reached up to approximately 130 MPa, which is among the highest reported in the literature for steel/Al bimetallic structures. The specimens fabricated with high heat input conditions had a thicker IMC layer at the steel/Al interface, resulting in a more brittle interface and degradation of the mechanical properties.

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Investigating stainless steel/aluminum bimetallic structures fabricated by cold metal transfer (CMT)-based wire-arc directed energy deposition

Abstract

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Keywords

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