Microstructural and Mechanical Characterization of a CMT-WAAM Fabricated 17-4PH Stainless Steel/Inconel 625 Bimetallic Structure

The demand for large-scale high-performance components with tailored properties in the aerospace and automotive industries has increased interest in multi-material additive manufacturing (AM). Among AM techniques, the Wire Arc Additive Manufacturing (WAAM) process is preferred for bimetallic fabrication due to high deposition rates, low equipment costs, and efficient material utilization. However, differences in metallurgical and thermal properties between dissimilar alloys can cause heat accumulation, leading to thermal stresses, cracking, and weak interfacial bonds. To the best of the authors’ knowledge, no study has reported the fabrication and characterization of a 17-4PH SS/Inconel 625 joint using the large-scale CMT-WAAM Process. To fill this gap, this study characterizes the microstructure and elemental distribution of the joint using scanning electron microscopy (SEM), X-ray diffraction (XRD), X-ray Microscopy (XRM) and energy dispersive spectroscopy (EDS). Microstructural analysis revealed a martensitic matrix with retained δ-ferrite in the 17-4PH region, a fully austenitic γ-phase in the Inconel 625 region, and a mixed BCC–FCC transition zone at the interface. EDS results demonstrated a Fe–Ni compositional gradient across the interface. Radiographic inspection confirmed a defect-free build, and XRM results showed a porosity of less than 0.003% only in the 17-4PH region. Tensile testing confirmed joint integrity, with fracture occurring in the Inconel 625 region, and average yield and ultimate tensile strengths of 391 ± 7 MPa and 676 ± 9 MPa, respectively. The simplified Johnson-Cook constitutive model successfully predicted the ultimate tensile strength (UTS), with a prediction error of 9.3% compared to the experimental result. Furthermore, a novel 3D-structured light scanner technique was developed and validated with an extensometer to provide insight into localized strain behavior.