Metallurgical and mechanical properties of trimetallic functionally graded material fabricated by wire arc additive manufacturing

This study explores the fabrication of a trimetallic functionally graded material (FGM) using stainless steel (ER316L), duplex steel (ER2205), and Inconel 718 (IN718) through a gas metal arc welding (GMAW) based wire arc additive manufacturing (WAAM) process. The metallurgical examination reveals the large columnar austenitic grains and δ-ferrite phase at the grain boundaries along the built direction in the stainless-steel zone. At the interface of ER2205-IN718, a distinct boundary is observed due to the different alloy compositions. Scanning electron microscopy (SEM) shows metal carbide of nickel (Ni), molybdenum (Mo), and niobium (Nb) along the grain boundaries and nodular-shaped Lave phases in the IN718 zone. The energy dispersive spectroscopy (EDS) analysis reveals a gradual variation of Ni and Fe content, indicating the successful fabrication of the FGM. The mechanical characterization reveals that the hardness of the developed FGM steadily increases from bottom to top. However, at the ER2205-IN718 interface, it experiences a sharp decrease, followed by a subsequent increase within the IN718 zone. The tensile test demonstrated an increase in tensile strength along the built direction, accompanied by a reduction in strain. Notably, the minimum strain observed in the developed FGM is approximately equal to that of IN718 alloy. [Display omitted] •A tri-metallic functionally graded material is developed by GMAW-WAAM process.•Large columnar austenitic grains and δ-ferrite phase are present in ER316L.•The distinct boundaries at alloy interfaces with metal carbides and nodular-shaped Laves phases are present in IN718.•The FGM exhibits an improved tensile strength and microhardness along the built direction.