Dual-wire Plasma Arc Additive Forming Process of Functional Gradient Materials

YUE Youshu; ZHU Qiang; YU Xiaoyan; ZHANG Zhanhui

doi:10.3969/j.issn.1674-6457.2026.07.010

PDF(2139 KB)

Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (7) : 107-115. DOI: 10.3969/j.issn.1674-6457.2026.07.010

Additive Manufacturing

Dual-wire Plasma Arc Additive Forming Process of Functional Gradient Materials

YUE Youshu¹, ZHU Qiang¹, YU Xiaoyan^2,*, ZHANG Zhanhui³

Author information +

History +

Abstract

The work aims to study the effect of the dual-wire plasma arc additive manufacturing (DW-PAAM) process on the appearance and forming quality of single-pass depositions for 316L/IN625 functional gradient materials (FGMs), provide experimental data for revealing the relationship of "composition-process-formation" during the additive manufacturing of FGMs, and lay a theoretical and technical foundation for subsequent multi-layer deposition as well as the regulation of forming quality. Single-pass deposition experiments were conducted on 304L stainless steel substrates using 1.2 mm-diameter 316L and IN625 welding wires. A total of 80 sets of experiments were designed for FGMs with five composition gradients (316L, 75wt% 316L-25wt% IN625, 50wt% 316L-50wt% IN625, 25wt% 316L-75wt% IN625, IN625). Taking welding current (I_c), wire feed speed (S_f), and welding speed (T_s) as input parameters, and weld width (W), weld height (H), contact angle (θ), and dilution rate (D) of the deposition layer as output parameters, a quadratic polynomial regression model was established to fit the single-pass deposition forming of different composition gradients. Results showed that all 80 sets of test samples exhibited stable deposition processes, good surface forming, minimal spatter, and no obvious defects such as cracks or collapse were observed on the surface of the single-pass deposition layers. The fitted values of the established quadratic regression model showed a small deviation from the actual values, indicating high fitting accuracy. The model revealed that the gradient composition, wire feed speed, welding speed, and welding current all had significant effects on the deposition forming. The wire feed speed mainly affected the weld width, weld height, and contact angle; the welding speed had a significant effect on the weld height and width; and the welding current exerted an obvious effect on all output parameters. Analysis of the quadratic polynomial regression models and their coefficients in different composition regions indicated that the differences in material properties caused by different composition gradients also had significant effects on the output parameters. In conclusion, the quadratic regression model can accurately fit the appearance of single-pass deposition layers under different process parameters of the dual-wire plasma arc additive manufacturing system, and provides important reference value for the further optimization of process parameters.

Key words

functional gradient materials (FGMs) / plasma arc / polynomial regression model / additive manufacturing / 316L/IN625

Cite this article

EndNote

Ris (Procite)

Bibtex

Download Citations

YUE Youshu, ZHU Qiang, YU Xiaoyan, ZHANG Zhanhui. Dual-wire Plasma Arc Additive Forming Process of Functional Gradient Materials[J]. Journal of Netshape Forming Engineering. 2026, 18(7): 107-115 https://doi.org/10.3969/j.issn.1674-6457.2026.07.010

References

[1] KANG Z X, JIANG C R, LIU M Q, et al.Revealing the Effect of Layer-Varying Deposition Strategy on Laser-Directed Energy Deposition Bionic Gradient NiTi Alloy[J]. Virtual and Physical Prototyping, 2025, 20(1): e2476725.
[2] TIAN X X, ZHAO Z, WANG H B, et al.Progresses on the Additive Manufacturing of Functionally Graded Metallic Materials[J]. Journal of Alloys and Compounds, 2023, 960: 170687.
[3] CHEN H X, HE Y X, DASH S S, et al.Additive Manufacturing of Metals and Alloys to Achieve Heterogeneous Microstructures for Exceptional Mechanical Properties[J]. Materials Research Letters, 2024, 12(3): 149-171.
[4] KINDERMANN R M, ROY M J, MORANA R, et al.Process Response of Inconel 718 to Wire+Arc Additive Manufacturing with Cold Metal Transfer[J]. Materials & Design, 2020, 195: 109031.
[5] CARVALHO G H S F L, VENTURINI G, CAMPATELLI G, et al. Development of Optimal Deposition Strategies for Cladding of Inconel 625 on Carbon Steel Using Wire Arc Additive Manufacturing[J]. Surface and Coatings Technology, 2023, 453: 129128.
[6] LI K, ZHAN J B, ZHANG M, et al.A Functionally Graded Material Design from Stainless Steel to Ni-Based Superalloy by Laser Metal Deposition Coupled with Thermodynamic Prediction[J]. Materials & Design, 2022, 217: 110612.
[7] YADAV S, LIU S, SINGH R K, et al.A State-of-Art Review on Functionally Graded Materials (FGMS) Manufactured by 3D Printing Techniques: Advantages, Existing Challenges, and Future Scope[J]. Journal of Manufacturing Processes, 2024, 131: 2051-2072.
[8] ALKUNTE S, FIDAN I, NAIKWADI V, et al.Advancements and Challenges in Additively Manufactured Functionally Graded Materials: A Comprehensive Review[J]. Journal of Manufacturing and Materials Processing, 2024, 8(1): 23.
[9] AMIRSHAMI M, ROHANI RAFTAR O, RAJABI S, et al.Effects of Re-Melting on Interfacial Morphology of 316L/Inconel 625 Functionally Graded Material via Innovative Platform Integrated in Selective Laser Melting[J]. Progress in Additive Manufacturing, 2025, 10(9): 5903-5921.
[10] CORTIS D, PILONE D, GRAZZI F, et al.Functionally Graded Material via L-PBF: Characterisation of Multi-Material Junction between Steels (AISI 316L/16MnCr₅), Copper (CuCrZr) and Aluminium Alloys (Al-Sc/AlSi₁₀Mg)[J]. Progress in Additive Manufacturing, 2025, 10(4): 2455-2472.
[11] MEHRABI O, HOSSEIN SEYEDKASHI S M, MORADI M. Experimental and Response Surface Study on Additive Manufacturing of Functionally Graded Steel-Inconel Wall Using Direct Laser Metal Deposition[J]. Optics & Laser Technology, 2023, 167: 109707.
[12] WANG Y, LI Y, WANG H Y, et al.Composition Design and Mechanical Properties of B₄C/Al-Zn-Mg-Cu Functionally Graded Materials Prepared by Laser Additive Manufacturing[J]. Journal of Materials Research and Technology, 2024, 32: 3620-3629.
[13] CHEN R, LU W H, SUN F B, et al.Novel Method of Additive Manufactured Functionally Gradient Materials Using Multi-Component Stranded Welding Wires[J]. Materials Science and Engineering: A, 2025, 929: 148134.
[14] 陈正宇, 范谨锐, 蔡易高, 等. 等离子弧焊梯度材料增材制造微观组织和性能研究[J]. 精密成形工程, 2025, 17(1): 205-213.
CHEN Z Y, FAN J R, CAI Y G, et al.Microstructure and Properties of Plasma Arc Welding Gradient Materials by Additive Manufacturing[J]. Journal of Netshape Forming Engineering, 2025, 17(1): 205-213.
[15] 徐刚, 罗开玉, 鲁金忠. 激光定向能量沉积IN718/316L异质金属结构界面组织及力学性能研究[J]. 机械工程学报, 2024, 60(1): 179-189.
XU G, LUO K Y, LU J Z.Research on Interfacial Microstructure and Mechanical Properties of In718/316L Bimetal Structure Manufactured by Laser Directed Energy Deposition[J]. Journal of Mechanical Engineering, 2024, 60(1): 179-189.
[16] 张敏, 王新宝, 王浩军, 等. 激光熔覆TC4/Inconel 625/316L不锈钢梯度材料组织与性能[J]. 焊接学报, 2023, 44(7): 16-23.
ZHANG M, WANG X B, WANG H J, et al.Microstructure and Mechanical Properties of Laser Cladding TC4/Inconel 625/316L Stainless Steel Gradient Material[J]. Transactions of the China Welding Institution, 2023, 44(7): 16-23.
[17] GHANAVATI R, NAFFAKH-MOOSAVY H, MORADI M, et al.Design Optimization for Defect-Free AISI 316 L/IN718 Functionally Graded Materials Produced by Laser Additive Manufacturing[J]. Materials Characterization, 2025, 220: 114697.
[18] LI T X, WANG Z J, YANG Z W, et al.Fabrication and Characterization of Stainless Steel 308L/Inconel 625 Functionally Graded Material with Continuous Change in Composition by Dual-Wire Arc Additive Manufacturing[J]. Journal of Alloys and Compounds, 2022, 915: 165398.
[19] LI T X, WANG Z J, HU S S, et al.Hot Cracking during the Fabrication of Inconel 625/Stainless Steel 308L Functionally Graded Material by Dual-Wire Arc Additive Manufacturing[J]. Journal of Manufacturing Processes, 2022, 82: 461-473.
[20] KHAN A U, SADHYA S, BHARATH KUMAR A, et al.Investigation on Dual Wire TIG Arc Additive Manufacturing of IN625 and SS316L FGM for Continuous Gradient and Sandwich Structures[J]. Thin-Walled Structures, 2024, 200: 111881.
[21] YU X Y, XUE J X, SHEN Q K, et al.Study on the Strengthening of Unfavorable Composition Zones in 316L-IN625 Functional Gradient Materials by Nb Element[J]. Steel Research International, 2025, 96(11): 84-94.
[22] WANG C D, ZHANG P Q, ZHANG K D, et al.A Novel Process Parameter Screening Strategy by Comprehensively Consideration of Powder Separation, Defects and Power Consumption when Fabricating FGM Using Laser Metal Deposition[J]. Journal of Cleaner Production, 2021, 278: 123274.
[23] RANKOUHI B, JAHANI S, PFEFFERKORN F E, et al.Compositional Grading of a 316L-Cu Multi-Material Part Using Machine Learning for the Determination of Selective Laser Melting Process Parameters[J]. Additive Manufacturing, 2021, 38: 101836.
[24] MA Z Y, LIU W W, LI W Y, et al.Optimization of Density and Surface Morphology of SS 316L/IN718 Functionally Graded Thin-Walled Structures Using Hybrid Prediction-Multi-Objective Optimization Method[J]. Journal of Manufacturing Processes, 2024, 120: 337-352.
[25] SINGH M, SINGH R K R, GUPTA D. Investigation of Frictional Deformation on Mechanical and Metallurgical Properties of Ni-Based Functionally Graded Materials Developed by Wire and Arc Additive Manufacturing[J]. Journal of Materials Engineering and Performance, 2025, 34(2): 1112-1122.
[26] SINGH M, SINGH R K R, GUPTA D. Effect of In-Situ Cooling during Pressure and Frictional Deformation on Mechanical and Metallurgical Properties of Ni-Based Functionally Graded Material Developed by Wire Arc Additive Manufacturing[J]. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 2024, 238(1): 50-64.

Funding

The National Natural Science Foundation of China (51875213); Scientific Research Projects of Colleges and Universities in Guangdong Province (2024ZDZX3045); Guangdong Province Learning Society Construction and Governance Enhancement Project (JXJYGC2024C148); 2024 Key Research Platforms and Projects for Universities in Guangdong Province (2024KCXTD073)