Control of the chemical composition distribution in deposited metal by wire and arc-based additive manufacturing

Wire and arc-based additive manufacturing (AM) is an additive manufacturing technique applying arc welding technology, where the metal melted by the arc discharge is accumulated and deposited. High-performance products with an excellent mechanical or chemical properties can be obtained using more than two materials through wire and arc-based AM. However, thermal stress and residual stress can form around the interface between two materials. Therefore, the objective of this study is to control the chemical composition of the deposited metal so that it changes gradually near the interface. Intermediate layers, with controlled chemical compositions, were inserted between the materials boundary. To regulate the chemical composition of the deposited metal, a filler wire was added into the molten pool during the deposition process. Results revealed that the chemical composition changed gradually near the interface using the proposed method.