PSI - Issue 71

Available online at www.sciencedirect.com

ScienceDirect

Procedia Structural Integrity 71 (2025) 438–444

Keywords: WAAM; Heterogenous Steel; Multi-Wire; Ferritic and Austenite Phases; Mechanical Properties Abstract This study explores the innovative fabrication of heterogeneous steel alloys using an in-house developed multi-wire arc additive manufacturing (M-WAAM) setup based on gas tungsten arc welding (GTAW). This study creates alloy compositions with specialized mechanical properties by combining the unique properties of mild steel (ER70S-6) and stainless steel 304 grade (SS 304). This multi-wire setup makes it possible to deposit both materials simultaneously, introducing a novel uniformity and versatility to the alloy fabrication process. The compatibility of ER70S-6 and SS-304 during the deposition process is examined. It focuses on changing the wire feed rate (WFR) of these filler wires to alter their phase composition, and it also looks at how these phase changes affect the mechanical properties of the heterogeneous steel alloy. The results demonstrate that a higher proportion of the austenite phase significantly enhances ultimate tensile strength and hardness. This improvement in mechanical properties was achieved by effectively combining the unique attributes of ER70S-6 and SS-304, resulting in a heterogeneous steel alloy . © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SICE 2024 organizers 1. Introduction Developing advanced materials plays a key role in sectors like aerospace, automotive, and defence, where durability, corrosion resistance, and high performance are critical (Reisgen et al., 2019; Abe and Sasahara, 2016). Traditional manufacturing techniques often restrict fine-tuning of material properties for specific applications. The rising challenge has increased interest in additive manufacturing (AM) technologies. These techniques give better precision when layering materials and allow customizing their properties to meet specific needs. A key benefit of directed energy deposition (DED) is its flexibility with different materials. This makes it great for creating components from several material mixtures (Bandyopadhyay and Heer, 2018). Among DED technologies, WAAM is promising for producing significant, complex metallic components, particularly high-strength steels (Karunakaran et al., 2022; Gupta et al., 2024; Gupta et al., 2024). Bimetallic structures made from mild and stainless steel have 5 th International Structural Integrity Conference & Exhibition (SICE 2024) Exploring Heterogeneous Steel Alloys Through Multi-Wire Arc Additive Manufacturing Ganesan G a , Siddartha a , Shahu Rajaram Karade a , Sudhanshu Dubey a *, Neel Kamal Gupta b, K. Narasimhan a , K.P. Karunakakran a a Indian Institute of Technology Bombay, Powai, Mumbai-400076, India b Technische Universität Bergakademie Freiberg, 09599 Freiberg, Germany

2452-3216 © 2025 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of SICE 2024 organizers 10.1016/j.prostr.2025.08.059