Dissimilar metal deposition with a stainless steel and nickel-based alloy using wire and arc-based additive manufacturing

•Dissimilar metal deposition using wire and arc-based AM was conducted.•Mechanical properties of the built object were comparable to that of bulk material.•With the proposed process, highly functional shapes could be made.

The wire and arc-based additive manufacturing process applies arc welding technology; the wire material is melted by the arc discharge, and is then accumulated successively in this process. The wire and arc-based additive manufacturing process directly and locally adds material to the molten pool. By changing the material locally during the process, more than one kind of material can be used simultaneously in a single manufactured component. In this study, two kinds of dissimilar metal deposition were conducted. A combination used was a stainless steel and Ni-based alloy. Mechanical properties near the interface such as hardness and bond strength were investigated. As a result, it was found that the mechanical properties of the manufactured alloy were comparable to those of a bulk material. In addition, an additive manufacturing system and a torch path planning method for using more than two kinds of material were proposed. By using this method, highly functional shapes whose surfaces and inner structures are made of different material could be made.