Multi-metal Laser Powder Bed Fusion:Processes, Materials, Challenges

Significant progress has recently been achieved in the field of multi-material metalAdditive Manufacturing (MMAM), largely due to innovative advancements in AMtechniques that enable the printing of two or more materials within one single part. Thekey objective in this processing is achieving multi-functionality by integrating a secondor more materials. The second desired functionality can be higher strength, ductility,and/or higher electrical-thermal conductivity suitable for customized industrialapplications. This review talk discusses the current processes, materials, and challengesregarding the bonding mechanisms and interface properties of produced alloys usingLaser Powder Bed Fusion Technologies (LPBF). The main outcome suggests applyingadaptive dynamic process parameter settings as volumetric energy density input fordifferent layers at the interface, near interface, and bulk area to avoid cracks and otherenergy-related defects. Optimizing alloy composition using equilibrium and Scheilsolidification phase diagrams to avoid unwanted intermetallic phase formation at theinterface is necessary for understanding associated mechanisms for phase formations atthe interface. This study can help researchers to understand the opportunities andchallenges for some material combination, and to provide customized industrialapplications for their selected pairs in the future.