Exploring multi-material structures: An overview of arc additive manufacturing
Dhruv Kumar, Vipin, Reeta Wattal
Abstract. Arc welding-based additive manufacturing techniques offer promising prospects for metal additive manufacturing, particularly in the economic production of large-sized components with relatively high deposition rates. This review article provides an introduction to wire arc additive manufacturing (WAAM) and offers an overview of its fundamental principles. Additionally, it delves into the fabrication of bi-metallic structures and functionally graded materials/structures using WAAM, exploring their applications across various industries.
Keywords
WAAM, Bi-Metallic Materials, Additive Manufacturing and Functionally Graded Materials
Published online 3/1/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Dhruv Kumar, Vipin, Reeta Wattal, Exploring multi-material structures: An overview of arc additive manufacturing, Materials Research Proceedings, Vol. 49, pp 29-38, 2025
DOI: https://doi.org/10.21741/9781644903438-4
The article was published as article 4 of the book Mechanical Engineering for Sustainable Development
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] Han, J., Lu, L., Xin, Y., Chen, X., Zhang, G., Cai, Y. and Tian, Y., 2022. Microstructure and mechanical properties of a novel functionally graded material from Ti6Al4V to Inconel 625 fabricated by dual wire+ arc additive manufacturing. Journal of Alloys and Compounds, 903, p.163981. https://doi.org/10.1016/j.jallcom.2022.163981
[2] Huang, J., Liu, G., Yu, X., Wu, H., Huang, Y., Yu, S. and Fan, D., 2022. Microstructure regulation of titanium alloy functionally gradient materials fabricated by alternating current assisted wire arc additive manufacturing. Materials & Design, 218, p.110731. https://doi.org/10.1016/j.matdes.2022.110731
[3] Rodrigues, T.A., Bairrão, N., Farias, F.W.C., Shamsolhodaei, A., Shen, J., Zhou, N., Maawad, E., Schell, N., Santos, T.G. and Oliveira, J.P., 2022. Steel-copper functionally graded material produced by twin-wire and arc additive manufacturing (T-WAAM). Materials & Design, 213, p.110270. https://doi.org/10.1016/j.matdes.2021.110270
[4] Mohan Kumar, S., Rajesh Kannan, A., Pravin Kumar, N., Pramod, R., Siva Shanmugam, N., Vishnu, A.S. and Channabasavanna, S.G., 2021. Microstructural features and mechanical integrity of wire arc additive manufactured SS321/Inconel 625 functionally gradient material. Journal of Materials Engineering and Performance, 30, pp.5692-5703. https://doi.org/10.1007/s11665-021-05617-3
[5] Wang, J., Pan, Z., Ma, Y., Lu, Y., Shen, C., Cuiuri, D. and Li, H., 2018. Characterization of wire arc additively manufactured titanium aluminide functionally graded material: microstructure, mechanical properties and oxidation behaviour. Materials Science and Engineering: A, 734, pp.110-119. https://doi.org/10.1016/j.msea.2018.07.097
[6] Ahsan, M.R.U., Tanvir, A.N.M., Ross, T., Elsawy, A., Oh, M.S. and Kim, D.B., 2020. Fabrication of bimetallic additively manufactured structure (BAMS) of low carbon steel and 316L austenitic stainless steel with wire+ arc additive manufacturing. Rapid Prototyping Journal, 26(3), pp.519-530. https://doi.org/10.1108/RPJ-09-2018-0235
[7] Ahsan, M.R., Tanvir, A.N.M., Seo, G.J., Bates, B., Hawkins, W., Lee, C., Liaw, P.K., Noakes, M., Nycz, A. and Kim, D.B., 2020. Heat-treatment effects on a bimetallic additively-manufactured structure (BAMS) of the low-carbon steel and austenitic-stainless steel. Additive Manufacturing, 32, p.101036. https://doi.org/10.1016/j.addma.2020.101036
[8] Zhang, W., Lei, Y., Meng, W., Ma, Q., Yin, X. and Guo, L., 2021. Effect of deposition sequence on microstructure and properties of 316L and Inconel 625 bimetallic structure by wire arc additive manufacturing. Journal of Materials Engineering and Performance, 30(12), pp.8972-8983. https://doi.org/10.1007/s11665-021-06137-w
[9] Tian, Y., Shen, J., Hu, S., Chen, X., Cai, Y. and Han, J., 2022. Effect of deposition layer on microstructure of Ti-Al bimetallic structures fabricated by wire and arc additive manufacturing. Science and Technology of Welding and Joining, 27(1), pp.22-32. https://doi.org/10.1080/13621718.2021.1996850
[10] Gupta, A. and Talha, M., 2015. Recent development in modeling and analysis of functionally graded materials and structures. Progress in Aerospace Sciences, 79, pp.1-14. https://doi.org/10.1016/j.paerosci.2015.07.001
[11] Saleh, B., Jiang, J., Fathi, R., Al-hababi, T., Xu, Q., Wang, L., Song, D. and Ma, A., 2020. 30 Years of functionally graded materials: An overview of manufacturing methods, Applications and Future Challenges. Composites Part B: Engineering, 201, p.108376. https://doi.org/10.1016/j.compositesb.2020.108376
[12] Kumar, A., Singh, R.C. and Chaudhary, R., 2023. Investigation of microstructure and several quality characteristics of AA7075/Al2O3/coconut shell ash hybrid nano composite prepared through ultrasonic assisted stir-casting. Journal of Materials Engineering and Performance, 32(20), pp.9263-9278. https://doi.org/10.1007/s11665-022-07780-7
[13] Duraisamy, R., Kumar, S.M., Kannan, A.R., Shanmugam, N.S., Sankaranarayanasamy, K. and Ramesh, M.R., 2020. Tribological performance of wire arc additive manufactured 347 austenitic stainless steel under unlubricated conditions at elevated temperatures. Journal of Manufacturing Processes, 56, pp.306-321. https://doi.org/10.1016/j.jmapro.2020.04.073
[14] Kumar, A., Singh, V.P., Singh, R.C., Chaudhary, R., Kumar, D. and Mourad, A.H.I., 2024. A review of aluminum metal matrix composites: fabrication route, reinforcements, microstructural, mechanical, and corrosion properties. Journal of Materials Science, pp.1-68. https://doi.org/10.1007/s10853-024-09398-7
[15] Nemani, A.V., Ghaffari, M. and Nasiri, A., 2020. Comparison of microstructural characteristics and mechanical properties of shipbuilding steel plates fabricated by conventional rolling versus wire arc additive manufacturing. Additive Manufacturing, 32, p.101086. https://doi.org/10.1016/j.addma.2020.101086
[16] Huang, C.Y. and Chen, Y.L., 2016. Design and impact resistant analysis of functionally graded Al2O3-ZrO2 ceramic composite. Materials & Design, 91, pp.294-305. https://doi.org/10.1016/j.matdes.2015.11.091
