Improved strength in nickel-aluminum bronze/steel bimetallic component fabricated using arcing-wire arc additive manufacturing with alternating deposition strategy

To enhance microstructure and mechanical properties, arcing-wire arc additive manufacturing (AWAAM) with alternating deposition strategy was firstly employed to produce nickel-aluminum bronze (NAB)-steel components. The implementation of alternating deposition strategy fostered the creation of interlocked microstructures, establishing robust bonds at the interface. Moreover, the convection within the melt pool during alternating deposition induced the formation of numerous precipitates, serving as a precipitation reinforcement. Simultaneously, these precipitates served as heterogeneous nucleation sites, facilitating the formation of substantial fine equiaxed crystals, resulting in grain boundary strengthening. A comprehensive examination of microstructure and mechanical properties was conducted using a variety of microscopy techniques and mechanical testing for components with and without arcing-wire. After applying arcing-wire, precise control was exerted over the melting of both matrix and wire, effectively preventing interface cracking caused by excessive melting. Moreover, with the arc heat input diminished, the temperature gradient in the melt pool decreased, leading to grain and precipitate refinement, consequently enhancing their strength. Owing to microstructural modifications, AWAAM demonstrated enhancements in ultimate tensile strength and yield strength by up to 20.1 % and 21.1 %, respectively, when compared to WAAM.