Application of CMT-Twin DED-Arc Process on the Fabrication of Invar 36 by In Situ Alloying

This research explored the technical feasibility of creating a controlled chemical composition for Fe-Ni alloys using a Directed Energy Deposition (DED) arc metal additive manufacturing (AM) process in its twin wire feed mode. This method employs two independently controlled arc power sources to feed two different wires into a single torch, creating a unified melt pool protected by a single shielding gas nozzle. The research focused on producing Invar 36 (EN 1.3912), a low thermal expansion alloy, by melting and mixing steel and Ni-Fe wires using Cold Metal Transfer-Twin (CMT-Twin) technology. This method enables the fabrication of multi-material components featuring regions with distinct chemical compositions, including functional gradients, with the aim of leveraging the advantageous properties of each individual material. Furthermore, this new manufacturing route offers the possibility to avoid using some alloying elements, such as Nb, an element considered a critical raw material (CRM) in the European Union (EU). Microstructure and mechanical properties were analyzed and compared to commercial Invar 36 obtained by DED-Arc with single wire as well as the effect of the absence of Nb. Results showed that the in situ obtained alloy had 10-20% lower strength but exhibited 10-15% higher elongation compared to the commercial alloy, making it a promising alternative for advanced manufacturing by using this new manufacturing route.