Metal Transfer Process Research Articles

Assessment of Weld Microstructure Through Sound Velocity Measurements for Power Plant Applications

This research study employed an immersion-based micro-resolution ultrasonic velocity measurement technique (MUVT) to evaluate Grade 91 (9Cr-1Mo-V) steel welds. This process utilized a 20 MHz focused ultrasonic beam with a spot size of 250 µm, a 6 µm laser vibrometer spot size for detection, and an automated 3-axis raster scanner to accurately collect ultrasonic velocity data from two Grade 91 steel welds fabricated using cold metal transfer (CMT) and flux-cored arc welding (FCAW) processes. By analyzing the MUVT data, the Poisson’s ratio (υ) and modulus of elasticity (E), which are important mechanical properties for weldments, were calculated. The correlation between mechanical properties and ultrasonic velocity was examined. The results indicated that longitudinal ultrasonic velocity could effectively identify base metal, heat-affected zone (HAZ), and weld metal areas, showing a strong correlation with hardness. In particular, the distinctive V-shaped dip in velocity and hardness data across the HAZ areas of both samples highlighted changes in the microstructure of creep strength–enhanced ferritic steel welds. Importantly, the immersion-based MUVT demonstrated high accuracy in small sections of the weld, surpassing the conventional contact ultrasonic testing method in spatial resolution detection.

Dynamic behavior regulation of droplet transfer based on arc-bubble control by ultrasound-induced during underwater wet welding

In comparison to welding in air, the periodic formation of unstable arc bubbles is a significant factor contributing to the unstable mass transfer process during underwater wet welding (UWW). Up to now, there is no ideal method to control droplet transfer and improve arc stability. In this study, the ultrasound-induced method (UIM) was used to regulate the droplet transition behavior and improve the process stability. The behavior features and key mechanisms of arc-bubble and droplet transfer induced by ultrasound were revealed with the employment of highspeed camera and X-ray observation, respectively. The incident angle of ultrasound was taken as a variable to reveal its effects and mechanism of action on the behaviors of arc bubble and droplet transfer, weld formation quality, microstructure, and property of weld joint. The results show that ultrasound-induced a new rising mode of arc bubble, which can significantly reduce the repulsive resistance that come from the bubble rising on the droplet transfer process. Compared with underwater wet welding without ultrasound, the average diameter of molten droplets reduces from 3.2 mm to 1.7 mm, and the droplet transfer frequency increases from 7.8 Hz to 13 Hz as the incident angle of ultrasound increases to 60°. In addition, the weld seam without obvious defects could be produced by UWW with UIM, of which the Variation coefficient of weld reinforcement is reduced from 21.3 to 11.6 and 17.4 at an ultrasonic incident angle of 30° and 45°. With increasing of ultrasound incident angle, it showed that the microhardness of the weld joint has a slight increase. In the heat-affected zone, the microhardness for the joint increased from 290 HV to 320 HV while the incident angle increased to 60°. This research shows that an appropriate incident angle of ultrasound can obtain good-quality joints which has a stable metal transfer process in underwater wet welding.

Wire-arc additive manufacturing of Mg-Gd-Y-Zn-Zr alloy: Microstructure and mechanical properties

Mg-Gd-Y-Zn-Zr alloy is an essential high strength weight ratio material in the aerospace field. It has been fabricated gradually using wire-arc additive manufacturing (WAAM), a key integrated preparation technology for large-scale parts. In this investigation, a Mg-9.4Gd-3.3Y-1.75Zn-0.38Zr (wt.%) alloy was prepared by WAAM based in the cold metal transfer (CMT) process. Investigations were conducted into the microstructural evolution and mechanical properties during the solution and aging heat treatment. With an average grain size of 18.30 ± 9.89 μm, the as-deposited Mg-Gd-Y-Zn-Zr alloy is mainly composed of α-Mg matrix, (Mg,Zn)3(Gd,Y) eutectic phase, RE-rich particles, and rare-earth (RE) segregation zone. Following a 12-h heat treatment at 500 °C, the average grain size of the α-Mg matrix showed no appreciable changes. The α-Mg matrix also dissolved the (Mg, Zn)3(Gd, Y) phases, which led to the production of long period stacking ordered (LPSO) phases and the disappearance of the RE-segregation zone. The appearance of the nanoscale β′ phase following aging heat treatment. The deposited alloys had the following tensile properties: 196.5 ± 24 MPa for ultimate tensile strength (UTS), 157.2 ± 14 MPa for yield strength (YS), and 2.08 ± 0.8% for elongation (EL). The formation of LSPO phase can improve the ductility while the formation of nanoscale β′ phase can improve the strength of Mg-Gd-Y-Zn-Zr alloy. Thus, after heat treatment at 500 °C for 12 h, the alloy's EL rose to 9.27 ± 0.94%. After further aging heat treatment for 225 °C at 24h, the alloy's YS rose to 234±3 MPa and its EL was 4.56 ± 0.25%.

High-Performance 2319 Aluminum Alloy via CMT-WAAM: Microstructure, Porosity, and Mechanical Properties

The process of cold metal transfer (CMT) wire arc additive manufacturing (WAAM) for 2319 aluminum alloy was studied. The research investigated the coarse and fine equiaxed grain bands and porosity of the 2319 alloy after solution aging treatment, with a focus on the mechanical properties and deformation behavior of the aluminum alloy at different positions and orientations. Pores and coarse second phases mainly appeared at grain boundaries but were also observed within coarse equiaxed grains. The yield strength of the top horizontal samples reached 325.5 MPa, one of the highest yield strengths reported for 2319 aluminum alloy in the literature. The coarse brittle second phases at grain boundaries were the main crack sources during the failure process of the samples. In the fine equiaxed grain layer, cracks propagated along the grain boundaries connected to the second phases, and the presence of pores accelerated crack propagation; in the coarse equiaxed grain layer, cracks directly penetrated through the grains.

Effect of heat treatment on microstructure evolution and strengthening-toughening behavior of high-strength Mg-Gd-Y-Zn-Zr alloy fabricated by wire-arc additive manufacturing

Mg-Gd-Y-Zn-Zr alloy is an important lightweight material in the aerospace field. Wire arc additive manufacturing (WAAM) provides a new route to fabricate large Mg alloy components. Here, a Mg-8Gd-4Y–1Zn-0.5Zr (wt.%) alloy was fabricated using WAAM based on the cold metal transfer (CMT) process. Subsequently, a short-time solid solution + aging treatment was designed to tailor the microstructure. In the as-fabricated condition, the microstructure mainly consisted of fine α-Mg, network (Mg,Zn)3(Gd,Y) eutectic phase, and lamellar γ′ basal precipitate. After 500 °C-1 h short-time solid solution, the eutectic phase rapidly dissolved, the long-period stacking ordered (LPSO) phase formed, and the fine grain was maintained. Due to the good deformation capacity of the fine grains and the kinking deformation capacity of the LPSO phase, the ductility was significantly improved from 5.2 ± 0.4% to 15.5 ± 1.1%. After further 200 °C-64 h artificial aging, dense β′ prismatic precipitates formed. Thanks to the synergistic strengthening of the fine grains and β′ prismatic precipitates, a yield strength of 242 ± 4 MPa was achieved. However, the kinking deformation of the LPSO phase was inhibited, resulting in a drastic decrease of ductility to 6.1 ± 0.5%. Overall, the combination of strength and ductility of the CMT-based WAAM-processed Mg-Gd-Y-Zn-Zr alloy under an optimized heat treatment regime can be superior to those of the cast Mg-Gd-Y-Zn-Zr alloys with similar contents of Gd and Y elements. This work can guide further performance optimization for WAAM-processed Mg-Gd-Y-Zn-Zr alloys.

Elucidating the microstructure evolution and performance response of wire-arc directed energy deposited Al–Zn–Mg–Cu alloy at as-deposited and post-processing heat treatment states

Wire-arc directed energy deposition technology was employed to manufacture ultra-high-strength Al–Zn–Mg–Cu alloy taking advantage of variable polarity cold metal transfer (CMT) process. The grain characteristics and precipitation behavior under as-deposited (AD) and post-processing heat treatment (PHT) states were comparatively analyzed. The relationship between the microstructure evolution and mechanical performances was fully disclosed. The obtained results show that the grain structure of AD sample exhibited a nearly fully-equiaxed feature (average size: ∼45 μm), which was caused by the low heat input and variable polarity of CMT advance mode. The microhardness distribution of AD sample consisted of slight fluctuation and stable areas along the building direction due to the different thermal history and precipitation process. After the PHT process, the average grain size and morphology almost remained unchanged. However, compared with the size and type of precipitation phases under the AD state, high-density nanoscale (∼5 nm) metastable η′ phases were precipitated in the grain interior of the PHT sample, which contributed to the crucial precipitation strengthening effect. The homogeneous microhardness distribution was achieved with a high level (∼180 HV0.2). Meanwhile, tensile properties and elongation significantly increased to 524.68 ± 7.31 MPa and 7.10 ± 2.09 % after the PHT process, respectively.

Microstructural characteristics and properties of wire arc additive manufactured 304L austenitic stainless steel cylindrical components by different arc welding processes

Wire arc additive manufacturing (WAAM) is an advanced additive manufacturing (AM) technology that offers low cost and high deposition rates, making it suitable for building large metal parts for structural engineering applications. However, various welding procedures result in differing heat inputs and repetitive heating treatments throughout the deposition process, which can affect the microstructural and mechanical characteristics of the parts. In the current study, cylindrical parts made of 304L austenitic stainless steel (ASS) were manufactured using the WAAM technique, employing both gas metal arc welding (GMAW) and cold metal transfer (CMT) processes. This study explores the correlation between WAAM techniques and their effects on the bead geometry, microstructure and mechanical properties. The microstructure of the cylinders consisted of vertically growing austenite dendrites with residual ferrite (δ) within the austenite (γ) matrix. Compared to the bottom region (region ①), the top region (region ②) contained more residual ferrite. Although the microstructural characteristics from region ① to region ② are similar, they exhibit different ferrite morphologies. The rapid cooling rate in the CMT-AM process resulted in finer structures and a greater presence of ferrite phases in both regions compared to the GMAW-AM method. Cylinders produced by the CMT process displayed nearly uniform properties across both regions and demonstrated superior tensile properties, hardness, and impact toughness relative to those made using the GMAW technique. The WAAM 304L ASS cylinders also showed enhanced performance compared to stainless steel manufactured using traditional industrial forging standards, indicating that WAAM-processed 304L ASS cylinders are suitable for industrial applications.

Investigation of cladding layer formation in uphill wire laser additive manufacturing on inclined substrate

In wire laser additive manufacturing (WLAM), the position posture of substrate is highly related to the formation process of the cladding layer which will affect the forming quality and service performance of the manufacturing parts. The forming quality of the cladding layer is often difficult to be controlled under the condition of the inclined substrate. Therefore, a three-dimensional dynamic model is established in this paper to investigate the WLAM process on inclined substrate. The influence of the inclined substrate on the forming quality of the cladding layer is analyzed from the evolution of wire molten metal transfer process and oscillation behaviors of the molten metal in the molten pool. It is found that the backward gravity component plays a major role in promoting the backward oscillation process of the molten metal in the molten pool on inclined substrate. The backward oscillation process of the molten metal is the main factor for the formation of cladding layer with wave morphology. The calculated cladding layer morphology is validated by the experimental results. The proposed model is of great theoretical significance for understanding the molten pool dynamic behaviors of the WLAM process and improving the forming quality of the cladding layer on inclined substrate further.

Wire directed energy deposition of steel-aluminum structures using cold metal transfer process

In this study, a sharp transition from 316L stainless steel to 4043 aluminum alloy was fabricated using wire directed energy deposition (DED) via the cold metal transfer (CMT) process. The CMT process with its inherently low heat input, led to a significant reduction in intermetallic thickness at the bi-metallic interface compared to blown powder DED technique reported in the literature resulting in superior properties when compared to those of dissimilar steel-aluminum welds. Thermo-kinetic modeling confirmed that the intermetallic formation is through a classical nucleation and growth mechanism, and the fraction and thickness can be controlled by adjusting CMT process parameters to kinetically arrest or minimize the intermetallic formation. These findings underscore the efficacy of CMT-based wire DED for fabrication of steel-aluminum bi-metallic structures.

Optimization of Wire Arc Additive Manufacturing Based Cold Metal Transfer arc length and dynamic correction parameters using geometrical and Digital Image Corelation analysis

The control of the heat input and the geometrical characteristics of the joint during and after a layer deposition remains the concern of the manufacturers in Wire Arc Additive Manufacturing, despite the existence of all new technologies such as the Cold Metal Transfer process. The understanding of the effect of arc parameters having a remarkable role in the optimization of the layer deposition heat input is essential. In the following work, we will focus on the influence of the combination of the parameters of Cold Metal Transfer arc length and arc dynamics correction on the geometrical and mechanical characteristics of the final weld bead. Experimental and statistical investigations have been carried out on F57 filler metal for the assembly of S235 thin metal sheets by the butt joining method using the universal Cold Metal Transfer mode. The main parameters: (i) Arc length correction and (ii) Dynamic Arc correction have been varied to investigate the effect of the combination of these parameters using surface response from experimental plan methods under Minitab software. Furthermore, mechanical investigation using tensile tests coupled with Digital Image Correlation analysis has been realized. The obtained results show that the variation of arc length correction affects considerably the geometrical and mechanical characteristics of the one-layer deposition. However, the effect of the variation of the dynamic arc correction doesn’t affect the width of the welded bead but more the penetration. In the same way, the optimization of the arc’s length enabled us to control the wall’s width and appearance. In addition, optimizing the arc’s dynamics enabled us to control the right blend between layers. These results contribute to the optimization of the Wire Arc Additive Manufacturing-Cold Metal Transfer process parameters for future applications.

Proximity Ligation Assay for the Analysis of Iron-Mediated Protein-Protein Interactions in the Nucleus.

Iron forms essential cofactors used by many nuclear enzymes involved in genome maintenance. However, unchaperoned nuclear iron may represent a threat to the surrounding genetic material as it promotes redox toxicity that may affect DNA integrity. Safely handling intracellular iron implies metal transfer and cofactor assembly processes based on protein-protein interactions. Identifying those interactions commonly occurs via high-throughput approaches using affinity purification or proximity labeling coupled with mass spectrometry analysis. However, these methods do not identify the subcellular location of the interactions. The one-on-one confirmation of proposed nuclear interactions is also challenging. Many approaches used to look at protein interactions are not tailored for looking at the nucleus because the methods used to solubilize nuclear content are harsh enough to disrupt those transient interactions. Here, we describe step-by-step the use of Proximity Ligation Assay (PLA) to analyze iron-mediated protein-protein interactions in the nucleus of cultured human cells. PLA allows the subcellular visualization of the interactions via the in situ detection of the two interacting proteins using fluorescence confocal microscopy. Briefly, cells are fixed, blocked, permeabilized, and incubated with primary antibodies directed to target proteins. Primary antibodies are recognized using PLA probes consisting of one PLUS and one MINUS oligonucleotide-labeled secondary antibody. If the two proteins are close enough (<40nm), the PLA probes are ligated and used as the template for rolling circle amplification (RCA) with fluorescently labeled oligonucleotides that yield a signal detectable using fluorescence confocal microscopy. A fluorescently labeled membrane-specific stain (WGA) and the DNA-specific probe DAPI are used to identify cellular and nuclear boundaries, respectively. Confocal images are then analyzed using the CellProfiler software to confirm the abundance and localization of the studied protein-protein interactions.

Simulation of wire metal transfer in the cold metal transfer (CMT) variant of gas metal arc welding using the smoothed particle hydrodynamics (SPH) approach

AbstractCold metal transfer (CMT) is a variant of gas metal arc welding (GMAW) in which the molten metal of the wire is transferred to the weld pool mainly in the short‐circuit phase. A special feature here is that the wire is retracted during this strongly controlled welding process. This allows precise and spatter‐free formation of the weld seams with lower energy input. To simulate this process, a model based on the particle‐based smoothed particle hydrodynamics (SPH) method is developed. This method provides a native solution for the mass and heat transfer. A simplified surrogate model was implemented as an arc heat source for welding simulation. This welding simulation model based on smoothed particle hydrodynamics method was augmented with surface effects, the Joule heating of the wire, and the effect of the electromagnetic forces. The model of metal transfer in the cold metal transfer process shows good qualitative agreement with real experiments.

Experimental study on mechanical, damping and corrosion properties of Inconel 718 hard-faced stainless steel 304 using cold metal transfer

Cold Metal Transfer process is used to hard-face the Inconel 718 alloy onto the Stainless Steel 304 material. The optimized parameters from the Bead on Plate trials were determined as a wire feed rate of 7 m/min, deposition speed of 15 cm/min, welding current, and voltage of 175 A and 14.9 V, respectively. Hard-facing is carried out with the sinewave weaving technique along 30 % of overlapping beads. The analysis is focused on revealing the hard-faced specimens' microstructural, mechanical, and electrochemical corrosion properties. The hard-face layer exhibits grains of mixed modes, including columnar, cellular, and fine equiaxed grains. The increased heat transfer disintegrates grain formation and reduces secondary arm spacing development. SEM-Elemental mapping shows the reduction of Niobium (3.61 %) segregation and laves formation. The overlay layer has a maximum hardness of 343.1 HV0.5 over the base substrate with 204 HV0.5. The impact test reveals the hard-faced layer absorbs more energy (26.3 %) than the substrate. Dynamic Mechanical Analysis results indicate overlay layer enhancing damping properties. The electrochemical corrosion test findings suggest that the hard-faced layer's high corrosion potential (Ecorr = 8.533 mV) corresponds to a high corrosion resistance. Phase and intermetallic formations, distribution of elements, fractured and corrosive surface morphologies are analyzed using SEM, EDX, and elemental mapping results.

Arc and molten pool behavior on quality of hybrid cold metal transfer and tandem pulsed narrow gap gas metal arc welds: a study

ABSTRACT This research proposes a novel hybrid cold metal transfer (CMT) and tandem Pulsed gas metal arc welding (P-GMAW) process for narrow gap welding (NGW) of high strength low alloy (HSLA) steel plates. Investigating three sets of lead and trail wire feed speed (WFS) ratios [WFSL/T - 1.4, 1, 0.7], the study delves into the complex arc and metal transfer behavior within the narrow gap. Utilizing synchronized arc images and current-voltage waveforms, the research assesses their influence on fusion and mechanical properties. The root pass employs the single wire CMT process, while filling and closing passes leverage tandem P-GMAW, effectively minimizing incomplete fusion and reducing heat input. Results indicate that a lower WFSL/T (0.7) reduces the molten pool hump and overflow within the narrow gap while enabling direct weld arc engagement with the previously deposited layer, enhancing weld penetration. WFSL/T of 1.4 and 0.7 revealed higher and lower Charpy impact toughness.

Influence of process and heat input on the microstructure and mechanical properties in wire arc additive manufacturing of hot work tool steels

The present study demonstrates the suitability of wire arc additive manufacturing (AM) for hot work tool steel processing. Different arc welding techniques and energy inputs were applied and systematically compared to determine the deposition characteristics, microstructure and mechanical properties. All AM deposits show a sound visual appearance and full density without macroscopic imperfections, i.e. cracking. By adhering to a pre-defined interpass strategy, the cold metal transfer process can be used to achieve higher weld beads with lower dilution and faster build-up rates than the metal active gas process. The microstructure of the AM parts is comparable for all process configurations and consists of an α/α′-matrix with a finely dispersed vermicular and polygonal δ-ferrite network; no notable amount of retained austenite could be measured, but it could be observed by transmission electron microscopy embedded within the laths. Intensive precipitation of multiple molybdenum-based precipitates is observed along the interface matrix to δ-ferrite. In contrast, iron-based precipitates are predominantly found inside and at the boundaries of the laths of the matrix. Similarities are also evident in the mechanical properties, resulting in an average hardness of 380–390 HV1 and absorbed impact energy of 10–12 J at room temperature. High yield strength values of 1000–1100 MPa and ultimate tensile strength of 1200–1400 MPa were obtained. No significant differences in the measured mechanical properties could be noted regarding the specimen orientation, indicating the isotropy of the properties.

Optimization of CMT welding process parameters of dissimilar hot rolled E250 and polymer sandwich steel lap joints

Lap joints of 1.5 mm thin sheets of dissimilar hot rolled E250 with polymer sandwich steel (MPM) were produced by cold metal transfer (CMT) process, closer to the real application. The polymer layer polystyrene-butadiene-styrene sandwiched between two DC06 sheets of MPM was found to be intact at significantly lower heat inputs (0.16 − 0.24 kJ/mm), which otherwise had been quite challenging during TIG welding leading to huge rejections. After several iterative trials for acceptable weld quality, experiments were conducted as per L9 orthogonal array, Taguchi technique with welding speed (WS), wire feed rate (WFR) and welding torch orientation (TO) as the process parameters. The joints were investigated through optical macrograph, micrographs, hardness, tensile lap shear tests and fractography on the fractured specimen. Optimum parameters were determined for maximizing shear strength. The sample with optimized parameters exhibited 6% improvement in shear strength achieving 152.09 MPa and polymer layer retention. ANOVA analysis suggested WS to be most significant parameter with 69.85% contribution affecting shear strength. Coefficient of determination (R 2) for the shear strength was 87.26% derived from the linear regression model. Significantly, lower error 0.96% computed from the confirmatory test concluded very effective optimization. Highlights Thin sheets of polymer sandwich steel (MPM) sheets were joined successfully with hot rolled E250 sheet without thermal disengagement of the polymer layer in MPM by CMT welding. Under optimal parameters MPM/E250 joints exhibited excellent mechanical properties. Fractography analysis revealed ductile failure mode. The error between experimental and predicted results by Taguchi was significantly lower and very well within the acceptable range.

High-Entropy FeCoCrNiMn and FeCoNiCrAl Alloys Coatings: Structure and Properties

High-entropy alloys are a new class of materials consisting of at least five elements in an equiatomic or close to equiatomic ratio, which provides them with unique properties. Non-equiatomic high-entropy Fe-Co-Cr-Ni-Mn and Fe-Co-Cr-Ni-Al alloy coatings were applied to the 5083 alloy substrate using wire arc additive manufacturing and the cold metal transfer process. The structure, elemental composition, mechanical and tribological properties of coating / substrate systems were analyzed using modern methods of materials physics. The deposition of FeCoCrNiMn and FeCoNiCrAl HEA coatings on the surface of 5083 alloy was accompanied by the formation of gradients of elemental composition and mechanical properties. A transition layer with a thickness up to 450 μm was formed at the coating / substrate interface located at the coating-substrate boundary. The elemental composition gradient of the transition layer was studied, and a high level of chemical homogeneity of the coating was revealed. Alloying of the coating with substrate elements was observed. The alloying of the substrate with coating elements is accompanied by nonmonotonic changes of element composition in the 500 μm depth layer.

Influence of input parameters to determine the shape of weld bead in cladding on 316L stainless steel using the Taguchi method

Background: The Cold Metal Transfer (CMT) process, with its low heat input, is selected for cladding carbon steel in demanding industries such as mining, oil, gas, offshore, steel, and metal. Limited research exists on the utilization of Taguchi's technique in welding and cladding processes. The main objective of the present research is to employ the Taguchi approach for determining the impact of CMT parameters on the cladding geometry of 316L stainless steel. Methods: The influence of process parameters on the weld bead was examined using both Signal-to-Noise (S/N) ratio and Analysis of Variance (ANOVA) by implementing an orthogonal array. A structural steel substrate was coated with nickel-based metal inert gas (MIG) welding wire using the CMT process while being shielded by a 99.9 percent pure argon gas. To attain the desired quality of weld bead, the CMT input parameters and geometry of the bead are separately and collectively optimized. Results: When the welding current (Iw) is set at 130A, welding speed (V) at 200 mm/min, and the distance between the nozzle and plate (X) at 5 mm, the Taguchi method indicates that the desired outcome is obtained with the following parameters: a penetration (P) of 1.115 mm, a reinforcement (R) of 1.51 mm, a bead width (W) of 4.265 mm, and a percentage of dilution (D) of 21.145%. Conclusions: The research findings indicate, under certain limitations, the techniques of the Taguchi method be utilized to efficiently manage the CMT cladding process parameters.

Current research status and prospect of metal transfer process control methods in gas metal arc welding

Current research status and prospect of metal transfer process control methods in gas metal arc welding

Flexible transparent electrode with embedded silver mesh by eco-friendly polymer solution-assisted metal transfer process

Flexible transparent electrodes (FTEs) with an embedded metal meshes play an indispensable role in many high-performance optoelectronic devices due to their excellent mechanical stability and low-surface roughness. However, great challenges remain for achieving simple, cost-effective, and environmentally friendly manufacturing of FTEs with embedded metal mesh. In this work, a vacuum-free, mask-free, and plating-free fabrication technique is proposed for FTEs with embedded silver (Ag) mesh by combining an ink-jet printing technique and a newly developed eco-friendly polymer (polyvinyl alcohol) solution-assisted metal transfer process that does not use organic solvents. The fabricated FTEs exhibit excellent optoelectronic performance with an electrical resistance of ~ 1.6 Ω and an optical transmittance at 550 nm of ~ 85.98%. The FTEs with embedded Ag mesh show strong adhesion to the substrate due to their morphology features. The proposed technique offers a promising fabrication strategy with a cost-effective and environmentally friendly process for high-performance printed flexible electronics.Graphical abstract