Simulation of Wire Arc Additive Manufacturing of Dissimilar Transition Joint in Steel-Aluminum

Abstract

Dissimilar welding of non-ferrous metals can present difficulties since it can result in the formation of very fragile intermetallic compounds. The aim of this study was therefore to perform a computer simulation of the interaction between steel and aluminum using alloy UNS N06625 or copper as the transition joint, with a view to the deposition of dissimilar materials using the wire arc additive manufacturing process. The computer simulation was carried out using Simufact Welding® software, observing the characteristics of the part before carrying out the deposition process, determining the probable properties and dilutions of the selected materials, and the distortions and residual stresses of the part produced. Through this study, it was possible to evaluate the characteristics of the deposition of dissimilar materials by applying alloy UNS N06625 or copper as a transition joint between steel and aluminum and to predict the properties of the part produced by different welding processes.