Microstructural Characterization, Residual Stress Evaluation and Deformation Behaviour of Wire Arc Additive Manufactured Grade 91 Steel and Monel 400 Bimetallic Components

IF 4 3区材料科学 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Metals and Materials International Pub Date : 2025-02-09 DOI:10.1007/s12540-025-01890-2

Sivakumar Munusamy, Jerald J

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Abstract

This study investigated the microstructure and mechanical behavior of bimetallic components made from Grade 91 steel and Monel 400, fabricated using Wire Arc Additive Manufacturing (WAAM). The analysis revealed a tempered lath martensite structure in Grade 91 steel, enhanced by fine M₂₃C₆ carbides and MX-type precipitates, contributing to its high strength. Monel 400 exhibited uniform equiaxed grains, indicating good mechanical stability. At the bimetallic interface, a distinct boundary without defects was observed, suggesting a robust metallurgical bond. Residual stress analysis showed tensile stresses in Grade 91 steel and compressive stresses in Monel 400 due to their differing thermal properties. Tensile tests combined with Digital Image Correlation indicated that both materials retained their intrinsic ductility and strength, with localized strain leading to necking and ductile fracture. The bimetallic interface demonstrated improved mechanical properties and good bonding strength, validating WAAM’s efficacy in producing bimetallic structures. The study confirms that WAAM effectively produces bimetallic structures with enhanced mechanical properties, suitable for high-performance industrial applications such as heat exchangers and petrochemical, marine, and automotive industries.

Graphic Abstract

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91级钢和蒙奈尔400双金属构件的焊丝电弧添加剂的显微组织表征、残余应力评估和变形行为

研究了采用电弧增材制造技术（WAAM）制备的91级钢和蒙乃尔400双金属构件的显微组织和力学行为。分析结果表明，91级钢中存在回火板条马氏体组织，细小的M23C6碳化物和mx型析出相增强了该组织的强度。Monel 400具有均匀等轴晶粒，具有良好的力学稳定性。在双金属界面处，观察到明显的边界，没有缺陷，表明有坚固的冶金结合。残余应力分析表明，由于热性能不同，91级钢存在拉应力，而蒙乃尔400钢存在压应力。结合数字图像相关性的拉伸试验表明，两种材料都保留了其固有的延性和强度，局部应变导致颈缩和延性断裂。双金属界面表现出较好的力学性能和良好的结合强度，验证了WAAM制备双金属结构的有效性。该研究证实，WAAM有效地生产出具有增强机械性能的双金属结构，适用于热交换器、石化、船舶和汽车等高性能工业应用。图形抽象

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来源期刊

Metals and Materials International 工程技术-材料科学：综合

CiteScore

7.10

自引率

8.60%

发文量

197

审稿时长

3.7 months

期刊介绍： Metals and Materials International publishes original papers and occasional critical reviews on all aspects of research and technology in materials engineering: physical metallurgy, materials science, and processing of metals and other materials. Emphasis is placed on those aspects of the science of materials that are concerned with the relationships among the processing, structure and properties (mechanical, chemical, electrical, electrochemical, magnetic and optical) of materials. Aspects of processing include the melting, casting, and fabrication with the thermodynamics, kinetics and modeling.