Document Type

Article

Journal/Book Title/Conference

npj Advanced Manufacturing

Volume

2

Issue

30

Publisher

Nature Publishing Group

Publication Date

7-16-2025

Journal Article Version

Version of Record

First Page

1

Last Page

8

Creative Commons License

Creative Commons Attribution-Noncommercial-No Derivative Works 4.0 License
This work is licensed under a Creative Commons Attribution-Noncommercial-No Derivative Works 4.0 License.

Abstract

Directed Energy Deposition (DED) was used to deposit Inconel 625 (IN625) onto 316L stainless steel (SS316L) substrates fabricated by Laser Powder Bed Fusion. Tensile properties of the resulting multi-material specimens were compared to those of the individual alloys. Two bonding approaches were evaluated: a direct transition and a 50/50 intermediate layer formed by blending equal parts of each alloy during deposition. The multi-material specimens demonstrated higher yield strength than the single alloys. However, samples with the 50/50 transition exhibited brittle failure at the joint, whereas the direct transition behaved more ductile. Scanning Electron Microscopy revealed microcracks at the interface of the 50/50 transition, and Energy Dispersive Spectroscopy detected aluminum oxide particles in the DED-IN625 samples. These results underscore the importance of transition design in multi-material components and provide guidance for optimizing mechanical performance in demanding applications such as in extreme conditions, particularly where structural integrity and high-performance bonding are critical.

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