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A5356 cladding layer formation on a SUS304 plate by a weaving strategy with wire-arc directed energy deposition.

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Title: A5356 cladding layer formation on a SUS304 plate by a weaving strategy with wire-arc directed energy deposition.
Authors: Goda, Machi1 (AUTHOR), Sugiyama, Yuta1 (AUTHOR), Sasahara, Hiroyuki1 (AUTHOR) sasahara@cc.tuat.ac.jp, Anzai, Hiroki2 (AUTHOR), Anazawa, Daiju2 (AUTHOR), Kobayashi, Tsubasa2 (AUTHOR)
Source: International Journal of Advanced Manufacturing Technology. Jun2026, Vol. 144 Issue 12, p8069-8087. 19p.
Subjects: Intermetallic compounds, Heating control, Austenitic stainless steel, Welding, Electric welding
Abstract: The combination of aluminum alloys and stainless steels is in high demand across a wide range of applications, as it enables optimization of material properties and cost. When these dissimilar metals are joined by fusion, brittle intermetallic compounds (IMCs) form at the interface, severely degrading joint strength. Yet, identifying process parameters that simultaneously achieve optimal IMC thickness, a high bonding ratio, and a flat cladding surface remains highly challenging due to complex parameter interactions such as heat input, torch path, and wire feed speed. This study establishes the process conditions required for high-quality cladding, i.e., satisfying the three objectives mentioned above. To this end, an A5356 aluminum alloy layer was deposited onto a SUS304 stainless steel substrate while controlling heat input through weaving amplitude, wavelength, and frequency. The deposition behavior was captured with a high-speed camera, and thermal analysis was employed to predict favorable conditions. The results demonstrate that deposition with reduced heat input—when accompanied by a sharp contact angle of the molten aluminum alloy and a bead width exceeding the weaving wavelength λ—consistently yields high-quality cladding. Moreover, thermal analysis revealed the critical thermal window: the substrate surface directly beneath the torch must remain above the liquidus temperature of A5356 (~ 640 °C) but below the solidus of SUS304 (~ 1400 °C). These findings provide clear design criteria, offering a robust basis for optimizing dissimilar-metal cladding. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
An: 195219817
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Data: A5356 cladding layer formation on a SUS304 plate by a weaving strategy with wire-arc directed energy deposition.
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  Data: <searchLink fieldCode="AR" term="%22Goda%2C+Machi%22">Goda, Machi</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Sugiyama%2C+Yuta%22">Sugiyama, Yuta</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Sasahara%2C+Hiroyuki%22">Sasahara, Hiroyuki</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> sasahara@cc.tuat.ac.jp</i><br /><searchLink fieldCode="AR" term="%22Anzai%2C+Hiroki%22">Anzai, Hiroki</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Anazawa%2C+Daiju%22">Anazawa, Daiju</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Kobayashi%2C+Tsubasa%22">Kobayashi, Tsubasa</searchLink><relatesTo>2</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Jun2026, Vol. 144 Issue 12, p8069-8087. 19p.
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  Data: <searchLink fieldCode="DE" term="%22Intermetallic+compounds%22">Intermetallic compounds</searchLink><br /><searchLink fieldCode="DE" term="%22Heating+control%22">Heating control</searchLink><br /><searchLink fieldCode="DE" term="%22Austenitic+stainless+steel%22">Austenitic stainless steel</searchLink><br /><searchLink fieldCode="DE" term="%22Welding%22">Welding</searchLink><br /><searchLink fieldCode="DE" term="%22Electric+welding%22">Electric welding</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: The combination of aluminum alloys and stainless steels is in high demand across a wide range of applications, as it enables optimization of material properties and cost. When these dissimilar metals are joined by fusion, brittle intermetallic compounds (IMCs) form at the interface, severely degrading joint strength. Yet, identifying process parameters that simultaneously achieve optimal IMC thickness, a high bonding ratio, and a flat cladding surface remains highly challenging due to complex parameter interactions such as heat input, torch path, and wire feed speed. This study establishes the process conditions required for high-quality cladding, i.e., satisfying the three objectives mentioned above. To this end, an A5356 aluminum alloy layer was deposited onto a SUS304 stainless steel substrate while controlling heat input through weaving amplitude, wavelength, and frequency. The deposition behavior was captured with a high-speed camera, and thermal analysis was employed to predict favorable conditions. The results demonstrate that deposition with reduced heat input—when accompanied by a sharp contact angle of the molten aluminum alloy and a bead width exceeding the weaving wavelength λ—consistently yields high-quality cladding. Moreover, thermal analysis revealed the critical thermal window: the substrate surface directly beneath the torch must remain above the liquidus temperature of A5356 (~ 640 °C) but below the solidus of SUS304 (~ 1400 °C). These findings provide clear design criteria, offering a robust basis for optimizing dissimilar-metal cladding. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-026-18046-0
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        Text: English
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        PageCount: 19
        StartPage: 8069
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      – SubjectFull: Intermetallic compounds
        Type: general
      – SubjectFull: Heating control
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      – SubjectFull: Austenitic stainless steel
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      – SubjectFull: Welding
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      – SubjectFull: Electric welding
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      – TitleFull: A5356 cladding layer formation on a SUS304 plate by a weaving strategy with wire-arc directed energy deposition.
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            NameFull: Goda, Machi
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            NameFull: Sugiyama, Yuta
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            NameFull: Anzai, Hiroki
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              Text: Jun2026
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              Y: 2026
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