Wire arc additive manufacturing and characterization of mild steel – martensitic stainless steel bimetallic structure

This project looks at how to make and fully test a bimetallic part that combines martensitic stainless steel (MSS) with mild steel (MS) using wire‑arc additive manufacturing (WAAM). The part is built in 40 layers: the first 20 layers are MSS and the next 20 layers are MS. The study examines the transition zone where the two metals meet and the properties of the interface. We analyze the microstructure in three areas – the MSS zone, the interface, and the MS zone – with optical microscopy, scanning electron microscopy, X‑ray diffraction, and electron back‑scattered diffraction. Mechanical behavior is measured by nano‑indentation and tensile tests, giving yield strength, ultimate tensile strength,

and fracture details. We also test how each zone corrodes using potentiodynamic polarization and electrochemical impedance spectroscopy in a corrosive solution. The goal is to link microstructural features—such as skeletal delta‑ferrite in the martensitic matrix and acicular ferrite in the mild steel—to the observed mechanical and electrochemical performance. The findings will help design and evaluate high‑performance bimetallic components for structural use.

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