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Interfacial characterization of additively manufactured stainless steel to aluminium thin wall with nickel interlayer

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Abstract

The formation of brittle incoherent Fe–Al intermetallics at dissimilar interface makes wire arc additive manufacturing (WAAM) of stainless steel (SS)–aluminium (Al) difficult. The incorporation of nickel (Ni) interlayers between SS and Al is thought to improve structural integrity. This article provides a detailed characterization of SS–Ni and Al–Ni interfaces. The Al-Ni interface is divided into three intermetallic zones: AlNi at center, Al3Ni on Al side, and AlNi3 on Ni side. The Ni3Fe, NiFe, and NiFe3 intermetallics at the SS–Ni interface increase with heat input. The intermetallics at the Al–Ni interface are found to be affected by heat input as well as primary dendrite arm spacing (PDAS) and dendrite growth angle (DGA) of the Ni dendrites. With low heat input, low DGA, and high PDAS, the intermetallic thickness at the Al–Ni interface decreases. It is also discovered that as heat input increases, the hardness of both interfaces increases.

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Acknowledgments

The authors would like to acknowledge the DST-SERB for the financial support (Sanction No. ECR/2018/001250) to carry out the research activities. The authors would also like to acknowledge Director, CSIR-CMERI, for providing the opportunity, and facilities to carry out the research work.

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Authors and Affiliations

  1. CSIR-Central Mechanical Engineering Research Institute, Durgapur, West Bengal, 713209, India

    Amrit Raj Paul, Manidipto Mukherjee & Dilpreet Singh

  2. Academy of Scientific and Innovative Research (AcSIR), Ghaziabad, 201002, India

    Amrit Raj Paul, Manidipto Mukherjee & Dilpreet Singh

  3. National Institute of Technology, Durgapur, West Bengal, 713209, India

    Manas Kumar Mondal

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  1. Amrit Raj Paul
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Correspondence to Manidipto Mukherjee.

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Paul, A.R., Mukherjee, M., Singh, D. et al. Interfacial characterization of additively manufactured stainless steel to aluminium thin wall with nickel interlayer. Journal of Materials Research 37, 3629–3645 (2022). https://doi.org/10.1557/s43578-022-00732-w

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