Design strategies for bi-metallic additive manufacturing in the context of wire and arc directed energy deposition

While the recent research in manufacturing bi-metallic structures using wire and arc directed energy deposition focuses on feasibility studies to understand material compatibility, study presented here encircles a larger design framework, integrating process, intermediate surface conditions, mutual (hatching) direction. The investigation addresses issues associated with actual shades light intrinsic mechanism responsible for process-induced anisotropy resulting interfacial strength. Interfacial shear tests of candidate pair low-carbon steel-316L stainless steel reveal that machining before second material, if deposited low dilution heat input has limited effect final build quality. direction influences isotropy, i.e., strength improves when force acts transversely material. Interlocking promoted by favorable direction, as revealed fractography, combined metallurgical bonding, enhances Despite element migration hardness spike interface up 500 HV due martensitic needles, defect-free structure was possible strengths over 400 MPa. contributes fundamental understanding approaches suitable sound structures.