Volume 5, Issue 6, June – 2020 International Journal of Innovative Science and Research Technology

ISSN No:-2456-2165

Manufacturing of a Bimetallic Structure of Stainless

Steel and Mild Steel through Wire Arc Additive
Manufacturing – A Critical Review
Anirudhan B T Jithin Devasia
Department of Metallurgical and Materials Engineering Department of Metallurgical and Materials Engineering
Amal Jyothi College of Engineering Kanjirappally, Amal Jyothi College of Engineering Kanjirappally,
Kottayam-686518 Kerala, India Kottayam-686518 Kerala, India

Tejaswin Krishna Mebin T Kuruvila∗

Department of Metallurgical and Materials Engineering Department of Metallurgical and Materials Engineering
Amal Jyothi College of Engineering Kanjirappally, Amal Jyothi College of Engineering Kanjirappally,
Kottayam-686518 Kerala, India Kottayam-686518 Kerala, India

Abstract:- Wire and Arc based Additive Manufacturing, dissimilar metals include casting, explosive welding, rolling,
shortly known as WAAM, is one of the most prominent extrusion, diffusion bonding, powder metallurgy, etc.
tech- nologies, under Additive Manufacturing, used for But some of these processes are not efficient as:
extensive production of complex and intricate shapes. This • difficulty in the fabrication of intricate shapes
layer by layer deposition method avails arc welding • Not cost effective
technology; Gas Metal Arc Welding (GMAW), a
competitive method in WAAM, is the conducted while some of the other processes are being used.
manufacturing process.
The main advantage of dissimilar metal joining can be
It is a sum of heat source, originated from the electric assessed with an assist. Copper alloy is acquitted with good
arc, and metal wire as feedstock. The metal wire from the properties while the con being its high price. So when a copper
feedstock, melted by arc discharge, is deposited layer by alloy is composed with steel, reduces the cost, which implies
layer. Another material can be added on to the top of composed material is effective for many applications, including
deposited layer by replacing the feed wire from the stock, to space industry [1].
fabricate a bimetallic structure. The purpose of this study is
to collect the salient datum from the joining of two Difference between conventional methods and additive
dissimilar metals. A combination of stainless steel and mild man- ufacturing is by the process itself; layer by layer deposi-
steel are considered. Proper deposition parameters, welding tion. Additive manufacturing has become one of the most
current along with voltage, bead width efficiency for both developing areas from the past thirty years [1]. Power bed
the metals were acquired. As a result, the physical fusion, directed energy deposition are two of the popular AM
properties of the dissimilar joint were approximate to the methods. When geometrical complexity and accuracy is in
bulk material. account, then the preferable methods are selective laser melting
(SLM) and electron beam melting (EBM), often referred as first
Keywords:- Additive Manufacturing; Wire And Arc Additive category, but due to low efficiency and high cost these are
Manufacturing; Gas Metal Arc Welding; Stainless Steel; Mild restricted to the production of high value and low production
Steel. parts. WAAM, placed in the second category, is the preferred
choice when cost and efficiency is considered. Fully fledged
I. INTRODUCTION welding technique, GMAW, and the usage of easily accessible
wire material boosts its efficiency and cuts cost. This makes it
Dissimilar metal joining, as the name suggests, is the combative against other AM techniques, even though, it
com- bination of two or more metals possessing different struggles in geometrical complexity [1].
physical, chemical and mechanical properties, such as wear
resistance, tensile strength, electrical or thermal conductivity, WAAM is the technique applied. It is derived from
corrosion resistance etc. The major objective is to omit the welding, although there are differences when dissipation of heat
disadvantages of both along with optimizing the integral is the factor. The heat transfer, for welding, from the molten
performance [1]. The conventional processes for joining of pool to the substrate is direct while the heat conductance, in the

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Volume 5, Issue 6, June – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
case of WAAM, is partial as the transfer of heat from layer by The stainless steel provides good corrosion resistance, here
layer to substrate causes the decrease in the heat input to the the Ni provides corrosion resistance while making the stainless
substrate along with dissipation of heat in air due to steel ductile. Whereas MS comprises of:
convection and radiation [1]. When the layer increases, thermal
resistance towards the substrate also increases, hence lagging Network Fe Cr Ni Mn Si C P S
the solidification process [2]. Weld-bead parameter is another content 63.5 19.5 9 to 1 to 0.3 to 0.03 0.03 0.03
important aspect of WAAM. The loss of efficiency in the % to 68 to 21 11 2.5 0.65
geometrical complexity is a result of variations in bead Table 1:- The Chemical Composition Of SS308L [6]
parameters. With over heat dissipation difference in the bead
geometry can be observed [1]. Network Fe Cr Ni Mn Si C P S
content 98.4 0.8 0.40 0.18 0.069 0.040 0.040 0.01
%
Table 2:- The Chemical Composition Of Mild Steel [7]

MS, when comparing to SS, is less brittle which implies

better strength for SS.MS exhibits ferromagnetism; magnetic
material. When these two metals are joined, expecting the in-
terface to have proper metallurgical bonding. The combination is
supposed to achieve the best attributes of both the metals. Major
objectives of this study is to analyze and acquire the appropriate
values of different parameters for the MS - SS joint, i.e., to
obtain the stable values for voltage, weld current, weld speed,
Fig. 1:- Diagram of WAAM robotic setup assisted by laser bead geometry, etc.
power source [5]
II. REVIEW ON MANUFACTURING OF A
WAAM hardware consists of: (i) welding power source, BIMETALLIC STRUCTURE OF SS308L AND
(ii) welding torch, (iii) metal wire feeding system. Mostly (ii) MILD STEEL THROUGH WIRE ARC
and (iii) are connected to a robotic system or via a simulation ADDITIVE MANUFACTURING
software which runs on computer [3]. Gas Metal Arc Welding,
abbreviated as GMAW, is the preferred process: the metal feed Fang Li et al. [1] focused on bringing a new thermoelectric
wire is the consumable electrode, and for the smoothness of cooling system into the WAAM process so that it can reduce the
the weld, the weld torch is placed coaxial to the consumable difference in the elimination of the heat that is existing between
electrode. The movement of the weld torch is determined by the layers of deposited metal. The results obtained through
the computer numerical control gantries (robotic system) [4]. effective utilization of the cooling system in WAAM process
Owing to its wide range of mechanical and physical proper- showed that there was in increase in the exploitation of the
ties, stainless steel is one of the highly recommended materials material by 16.3% and the error in the bead width was also
used for structural applications in nuclear industries, power reduced by 56.8%. A total increase in the product fabrication
plants, heavy load engineering applications, high temperature time was also observed by 60.9% as the dwell time between the
vessels, construction purposes and various other industrial depositions of successive layers was reduced eventually by the
uses. Considering its high end mechanical properties it can be incorporation of the cooling system.
directly applied into constructions, but the cost of the building
the structure will increase due to the high material cost of
stainless steel. The prominent agenda of selecting an efficient
material for constructional purposes lay on certain factors such
as low material cost, low fabrication cost, weldability of the
material, the strength of the weld joints it can form and easy
fabrication process. Considering all these factors, stainless steel
can be effectively applied into structural construction purposes
with the help of mild steel via dissimilar joining, that too
quite efficiently [5].

SS308L and MS are the experimented metal feeding wire

used here. The chemical composition of SS308L is specified in
Table 1.
Fig. 2:- Thermoelectric cooling system incorporated with
WAAM setup [1]

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Volume 5, Issue 6, June – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
Yunpeng Nie et al. [2] discussed about the fabrication of deposition can be done through automated procedures. Can
4043 Al-alloy components by cold metal transfer through be effectively used for manufacturing products both in small
WAAM technique. One of the major outputs that could be scale as well as large scale. Prominent advantages extended by
collected from the results was that the prototyping of the alloy
sections through WAAM + cold metal transfer could ensure
that the arc starting current was increased as well as the arc
ending current was decreased – which can avoid the downfall
of melt or formation of molten lumps. Large columnar grains
and dendrites were visible in the microstructure of the fab-
ricated parts and majority of the microstructure is contained
with aluminous eutectic phases as well as aluminium. Among
the interfaces of the aluminium and eutectic phase, silicon is
segregated. Also the mechanical properties of the fabricated
alloy parts were also quite good.

Fig. 4:- A standard automatic-WAAM setup [4]

WAAM technique include increased deposition rates

compared to other traditional manufacturing processes, high
yield as it minimize the material wastage and comparatively
lower feedstock cost.

Donghong Ding et al. [5] discussed on laying overlapping

multiple beads using wire arc additive manufacturing tech-
nique with the aid of a robot. Rather than the traditional flat top
Fig. 3:- Cold Metal Transfer - Welding Diagram [2] overlapping model of multiple bead, they followed a tangent
overlapping model. Following the traditional FOM, it became
Liming Liu et al. [3] discussed about the manufacturing of clear that this model is giving only a little consideration for the
a mild steel-silicon bronze bimetal through gas metal arc weld concept of optimum centre distance and critical valley concept.
based shaped metal deposition which is a prominent additive Thus the chances of getting uneven deposits of metal having
manufacturing technique. Materials used were Q235B steel as different heights are a lot higher. The new model proposed
the substrate, ER70S-6 mild steel wires of diameter 1.2mm and (TOM) by Donghong Ding et al. provides accurate vision over
SG-CuSi3 silicon bronze wires of diameter 0.8mm. Through the critical centre distance as well as the critical valley concept,
optimization they concluded that to get a 130mm long and 8mm and can produce a very stable and sound deposits.
wide silicon bronze bead on the MS, the weld current shall be
180A as well as a weld speed of 600mm/min. The interface Van Thao Le et al. [6] used gas metal arc based wire
zone of the structure showed the presence of mixing of -Fe and arc additive manufacturing method to manufacture thin-walled
-Cu. At the interface itself, the bronze side was found to have parts of 308L stainless steel. It was successfully completed and
contained with Fe elements concentrated with the Si from the metallurgical as well as the mechanical aspects of the
silicon bronze. The joint performed a good tensile strength of product were observed. From the microstructure, they found out
305MPa. that the middle and bottom regions of the wall were
characterized with the presence of columnar dendrites.
S. W. Williams et al. [4] shared a study and Equiaxed dendrites were observed at the top of the wall as well
research material on a particularly wide topic, i.e., wire and arc as the HAZ region between two distinct layers. Apart from the
additive manufacturing. Wire arc additive manufacturing is a wall regions, the microstructure of the product showed the
manufacturing method in which the heat source is supplied by presence of γ austenite dendrites which contained little amount
the a manufacturing is a manufacturing method in which the of δ ferrite phases.
heat source is supplied by the arc whereas the feedstock
material is supplied in the form of wire. A regular WAAM Radha Raman Mishra et al. [7] focused on a comparative
hardware setup would be consisted of a power source, wire study based on both TIG and MIG welding of dissimilar metal
feeder and welding torch. The motion of the welding torch is joining of stainless steel and mild steel. Comparing both the
controlled by a computer aided robot, so that any metal techniques after finishing the welding, it was proven that TIG is
more efficient than MIG welding – which comes out as the

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Volume 5, Issue 6, June – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
result as low porosity occurred in the dissimilar joining as welded joint fractured around the mild steel part rather than the
well as the low amount of precipitation of carbon. Radha stainless steel part because of the much lower strength offered
Raman Mishra et al. observed that trying the same weld in MIG by mild steel relatively. After conducting the bending tests, it
led to development of cracks at the time of welding and also was found that the dissimilar weld joint offers the best bending
the amount carbon precipitation at the joints is so high that it strength 4857 MPa which comes out of its property of high
reduces the ability of resistance to corrosion of the joint. Also resistance to bending.
found that the in both MIG and TIG welding techniques,
dissimilar joint between MS and SS304 has a very low ultimate Leilei Wang et al. [11] discussed about variations in prop-
tensile stress. erties of 316L stainless steel manufactured through WAAM.
Two types of arc modes were used in the manufacturing of the
Bintao Wu et al. [8] discussed the emerging trend in using product – SpeedPulse and SpeedArc – which were practically
the wire arc additive manufacturing techniques. Upon the confirmed as stable, offer excellent structural quality and
source of heat provided WAAM is classified into three: Gas efficient enough. Bothe the arc modes provide almost the same
Tungsten Arc Weld based, Gas Metal Arc Weld based and rate of deposition. SpeedArc process extends a higher cooling
Plasma Arc Weld based. WAAM through GMAW offers less rate and also offers a lower heat input. Thus, both at the bottom
stability, more fumes, high deposition rate and increased and upper layers, SpeedArc mode can bring fine grained
spatter. Major defects that are seen in WAAM-manufactured structures. Due to this fine grained structure produced by
products are deformation due to residual stresses, cracking, SpeedArc mode, the hardness as well as the tensile strength
porosity and delamination. Certain techniques are used to values of the products manufactured through SpeedArc method
improve the quality of the WAAM products such as heat will be higher than that of the component produced through
treatment, peening, interpass cold rolling, interpass cooling and SpeedPulse mode.
ultrasonic impact.
D. Ananthpadmanabhan et al. [12] discussed about
Network Ti Al Steel Ni Bimetal mechan- ical properties of the friction weld joint between
based based based based stainless steel and mild steel. Selected specimens had a length
Aerospace     of 75mm as well as diameter of 15mm and also were in
Automotive    cylindrical shapes. The experiment was successful and inferred
Marine   that friction welding can be effectively employed for joining of
Corrosion    dissimilar steels. The joint obtained has structurally strong
resistance enough but could only ensure an average ductility. The
High    comparatively lower ductility is explained with the presence of
temperature phosphorus as well as sulphur contents in the steel. The
Tools and  differences in hardness values of the base SS, base MS and the
molds weld joint is explained with the help of diffusion and
Table 3:- Materials Used For Fabrication Of Parts For recrystallization taking place.
Specific Applications Using Waam [8]
R.A. Rahman Rashid et al. [13] discussed about the
Takeyuki Abe et al. [9] experimented with layer by layer metal-lurgical properties of 316L stainless steel cladding on a
de- position of stainless steel and nickel-based alloy using mild steel substrate. Along the track laid, a decrease in the
WAAM technique. Welding is done using GMAW-based dilution content was found towards the end of the track. The
WAAM, where the movement of the welding torch is controlled clad region dilution can be represented in mathematical terms
by a computer-aided controller. The materials used are as:
YS308L which is equivalent to SUS304L and Ni6082 which is
equiva- lent to Inconel 600. After metallurgical observation it
was clear that no weld defects were found in the near border of
interface joint and the mild steel sections respectively. The

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Volume 5, Issue 6, June – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
At the interface, in weld metal area of YS308L it was Xiaohui Chen et al. [15] discussed about the mechanical
found that δ-ferrite had an increased grain size than usual which as well as microstructural aspects of an additively manufac-
occurred due to the heat effect as Ni6082 was deposited and in tured structure of austenitic stainless steel 316L. The WAAM
weld metal area of Ni6082 presence of austenite grain was technique followed here is GMAW-based and the torch was
found. The joint was also found to be strongly bonded so that controlled with help of a KUKA robot which had 6-axis motion.
it can be used for mechanical components. Offers corrosion and The parameters regarding the manufacturing of the structure
high temperature resistance. were given as: 300A of current, 28V of voltage and 10m/min of
feed rate of the stainless steel wire spool. In the manufactured
I.O. Oladele et al. [10] discussed about microstructural plate, the middle region had bigger columnar grains due to
and mechanical properties of dissimilar metal welded joint of vertical alignment of the austenitic dendrites and the around the
SS304L and mild steel plates of 5mm thickness. Process is edges smaller columnar grains were found due to the bend
carried out using GTAW. After welding, the tensile tests were experienced by some dendrites towards the plate surface. Found
carried out and it was found out that the stainless steel part that the tensile properties regarding the additively manufactured
offers the highest tensile strength with 805.3 MPa followed by 316L plate at ambient temperatures are just similar to that the
486.2 MPa and 286.3 MPa offered by the dissimilar metal weld wrought 316L and can be effectively chosen over wrought 316L
where D is the average dilution, dp is the depth of pen- etration for industrial applications.
of clad metal and tc is the thickness of the clad. The
microstructure of the clad region contained equiaxed austenitic Md. R. U. Ahsan et al. [16] discussed about the effects
grains with a large ratio of columnar grains found around the of heat treating on bimetallic structure of low carbon steel and
interface between the clad metal and the substrate. SS316L which is additively manufactured. Applying the correct
heat treatment parameters to the structure, the yield strength,
HAZ showed the presence of lath martensite coexisting ultimate tensile strength and the elongation, can all be
with Widmanstätten ferrite along the sides of interface of clad improved very effectively. Mechanical properties of the
and substrate. structure is improved by the formation of ferrite-bainite structure
which occurred as the transformation of ferrite in the deposited
Md. Rumman Ul Ahsan et al. [14] discussed on the fabrica- LCS took place. Heat treating at 800°C for 1 hour proved that the
tion of a bimetallic structure made of 316L austenitic stainless amount of ferrite in the BAMS structure increased and thus it led
steel and low carbon steel using wire arc additive manu- to its low ductility. Heat treating the sample above 950°C did not
facturing technique. Fabrication used GMAW-based WAAM bring about any changes that are valid. Whereas the optimum
technique in such a way that both low carbon steel and SS 316L heat treating condition for the BAMS structure was inferred as
can be laid successively. The experiment was successful and 950°C for 1 hour as it gave slight improvement in the
they found out that at the interface, there were two distinct mechanical properties.
regions with SS as well as LCS deposits. Also by inferring to
the hardness profile, due to the incoming attribute of chromium Andrés L Garcı́a Fuentes et al. [17] discussed on a study of
from SS, there was a sudden increase in the hardness at the effects of cyclic loads on the butt-welded joints of structural
interface. In the tensile test, the structure failed at the LCS side steel ASTM A537 and stainless steel 304L. The filler material
due to the lower tensile strength of low carbon steel. used for the welding is SS308L and the procedure is done using
the GMAW technique. In order to check the mechanical strength
of the welded specimen, certain mechanical tests like Charpy
impact test, microhardness profile through Vickers and bending
test were all done on pre-cracked specimens in order to know
the extend and rate of growth of crack. The tests showed that
despite the high microhardness values around HAZ and the
fusion line between SS304L and welding, through which the
crack propagated faster in the pre-crack test, the joint performed
with an optimum mechanical beaviour.

Bintao Wu et al. [18] discussed about the improvement

in the strength of the interface between bimetallic joint of
ER70S-6 steel and ERNi-1 nickel, when accommodating in-
terweaving deposition method. WAAM technique used here is
GTAW based. In order to get a stable melt pool, the angle
Fig. 5:- Transverse view of the clad deposition and the between the substrate and the weld wire feeder was fixed at 60°
parameters [13] and the shielding gas used in here is pure argon of almost 99.9%
purity. Total of 15 layers were laid with each layer having an
approximate height of 10mm. After producing a successful
component, it was evident that the interface at the joint was

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Volume 5, Issue 6, June – 2020 International Journal of Innovative Science and Research Technology
ISSN No:-2456-2165
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