Formability Behaviour of WAAM-fabricated functionally graded hybrid sheet with alternating AISI 410 SS/Inconel 625 layers

Abstract Functionally Graded Materials (FGMs) offer enhanced wear, thermal, and corrosion resistance by combining distinct material properties This study investigates the formability of an FGM composed of alternating layers of AISI 410 Stainless Steel and Inconel 625, fabricated using dual-wire Gas Metal Arc Welding (GMAW)-based Wire Arc Additive Manufacturing (WAAM). V-bending experiments were conducted to evaluate springback (SB) and formability index (FI), in comparison with monolithic AISI 410 SS and Inconel 625. The results indicate that the FGM exhibits 26% and 35% lower springback than Inconel 625 and AISI 410 SS, respectively, along with a marginally higher FI. Optimal formability was achieved with a punch radius of 2 mm, die opening of 30 mm, and holding time of 15 s. The second-order regression models with R 2 > 96% accurately predict SB and FI. The findings establish the FGM’s suitability for precision forming due to its desirable formability behavior.