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Volume 19
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10.3390/ma19183959
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Article

Microstructural, Mechanical and Corrosion Performance of NbZr1-Ti64 Multi-Material Structure Fabricated via Wire Arc Directed Deposition

by
Sainand Jadhav
1,*,
Duck Bong Kim
2,
Aaron Adams
1,
Sambhaji Kusekar
3,
Tushar Borkar
4,
Showmik Ahsan
5 and
Daniel Young
5
1
Department of Engineering Technology, Kennesaw State University, Marietta, GA 30060, USA
2
School of Environmental, Civil, Agricultural, and Mechanical Engineering, University of Georgia, Athens, GA 30602, USA
3
Department of Mechanical and Industrial Engineering, University of Wisconsin, Platteville, WI 53818, USA
4
Department of Mechanical Engineering, Cleveland State University, Cleveland, OH 44115, USA
5
Department of Mechanical and Materials Engineering, Wright State University, Dayton, OH 45435, USA
*
Author to whom correspondence should be addressed.
Materials 2026, 19(18), 3959; https://doi.org/10.3390/ma19183959 (registering DOI)
Submission received: 7 August 2026 / Revised: 6 September 2026 / Accepted: 14 September 2026 / Published: 17 September 2026
(This article belongs to the Special Issue Advances in Metallic Alloys, Materials and High-Performance Additive Manufacturing: Challenges and Opportunities)
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Abstract

This study investigates the fabricability, microstructures, and mechanical and corrosion behavior of a multi-material structure (MMS) composed of niobium alloy (NbZr1) and titanium alloy (Ti64) using a wire arc directed energy deposition process. The microstructure of NbZr1 alloy primarily consisted of equiaxed grains oriented in the rolling direction, while the deposited Ti64 microstructure exhibited ‘banding’ morphology and a basket-weave structure composed of α phase lamellae in a β matrix. The MMS interface revealed good metallurgical bonding and was free from defects such as cracks, pores and intermetallic phases. Niobium diffusion from NbZr1 into the Ti64 alloy resulted in the formation (β-Ti + Nb) of a solid solution which imparted strength to the MMS. Hardness testing showed that microhardness values follow the following trend: NbZr1 substrate > MMS interface > Ti64 deposit. The NbZr1–Ti64 multi-material structure developed in this study exhibited a balanced combination of ductility (22.73% elongation) and moderate tensile strength (254.18 MPa), outperforming most reported NbZr1-Ti64 MMS studies. All tensile specimens failed in a ductile manner on the NbZr1 side. The MMS demonstrated superior corrosion resistance, exhibiting the lowest corrosion current density and corrosion rate compared to its individual counterparts.
Keywords: multi-material structure; NbZr1; Ti64; wire arc directed deposition; corrosion; bimetallic structure; functionally graded materials multi-material structure; NbZr1; Ti64; wire arc directed deposition; corrosion; bimetallic structure; functionally graded materials

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MDPI and ACS Style

Jadhav, S.; Kim, D.B.; Adams, A.; Kusekar, S.; Borkar, T.; Ahsan, S.; Young, D. Microstructural, Mechanical and Corrosion Performance of NbZr1-Ti64 Multi-Material Structure Fabricated via Wire Arc Directed Deposition. Materials 2026, 19, 3959. https://doi.org/10.3390/ma19183959

AMA Style

Jadhav S, Kim DB, Adams A, Kusekar S, Borkar T, Ahsan S, Young D. Microstructural, Mechanical and Corrosion Performance of NbZr1-Ti64 Multi-Material Structure Fabricated via Wire Arc Directed Deposition. Materials. 2026; 19(18):3959. https://doi.org/10.3390/ma19183959

Chicago/Turabian Style

Jadhav, Sainand, Duck Bong Kim, Aaron Adams, Sambhaji Kusekar, Tushar Borkar, Showmik Ahsan, and Daniel Young. 2026. "Microstructural, Mechanical and Corrosion Performance of NbZr1-Ti64 Multi-Material Structure Fabricated via Wire Arc Directed Deposition" Materials 19, no. 18: 3959. https://doi.org/10.3390/ma19183959

APA Style

Jadhav, S., Kim, D. B., Adams, A., Kusekar, S., Borkar, T., Ahsan, S., & Young, D. (2026). Microstructural, Mechanical and Corrosion Performance of NbZr1-Ti64 Multi-Material Structure Fabricated via Wire Arc Directed Deposition. Materials, 19(18), 3959. https://doi.org/10.3390/ma19183959

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