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<p>Metal three dimensional-printing technology has advanced the fabrication of various metal alloys. One of the most well-known lightweight metal alloys, aluminum alloys, are applied in various fields, including aerospace and automobiles. Aluminum is a special metal with unique chemical and physical properties, including high reactivity to iron that hinders the multi-material additive manufacturing (MMAM) of aluminum and iron-based alloys. The direct deposition of the aluminum alloys onto stainless steel is impossible because the aluminum alloy sides off the base steel. Therefore, a novel anchor design of AISI 316&#xa0;L stainless steel was developed to prevent this detachment. In this study, laser directed energy deposition (LDED) is proposed for the MMAM of AlSi10Mg and AISI 316&#xa0;L stainless steel. The hardnesses of the anchor and deposited aluminum alloy were measured. Thereafter, scanning electron microscopy and energy-dispersive X-ray spectroscopy images were observed to determine material solidification and diffusion behavior. Finally, a tensile test was performed to evaluate the bond strength of the aluminum/steel interface. As a result, tensile interface bonding stress of up to 8.4&#xa0;MPa is produced when the anchor structure was made through rescanning on thin wall with a hatch spacing of the anchor of 1.5&#xa0;mm. AlSi10Mg was successfully deposited on AISI 316&#xa0;L stainless steel using LDED. In addition, a macroscopic anchor was designed and manufactured using LDED to overcome the weak bond of the micro-anchor. To demonstrate the Al/Fe MMAM, a multi-material sine wave and QR code were developed.</p> Graphical Abstract <p></p>

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Micro-Anchor Design for Multi-Material Additive Manufacturing of Aluminum Alloy on Fe-based Alloy Using Laser Directed Energy Deposition

  • 期刊论文

  • 发表日期：

    2025年6月19日

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  • Qing-Ye Jin,
  • Dohyung Kim,
  • Haeju Jo,
  • Wookjin Lee

摘要

Metal three dimensional-printing technology has advanced the fabrication of various metal alloys. One of the most well-known lightweight metal alloys, aluminum alloys, are applied in various fields, including aerospace and automobiles. Aluminum is a special metal with unique chemical and physical properties, including high reactivity to iron that hinders the multi-material additive manufacturing (MMAM) of aluminum and iron-based alloys. The direct deposition of the aluminum alloys onto stainless steel is impossible because the aluminum alloy sides off the base steel. Therefore, a novel anchor design of AISI 316 L stainless steel was developed to prevent this detachment. In this study, laser directed energy deposition (LDED) is proposed for the MMAM of AlSi10Mg and AISI 316 L stainless steel. The hardnesses of the anchor and deposited aluminum alloy were measured. Thereafter, scanning electron microscopy and energy-dispersive X-ray spectroscopy images were observed to determine material solidification and diffusion behavior. Finally, a tensile test was performed to evaluate the bond strength of the aluminum/steel interface. As a result, tensile interface bonding stress of up to 8.4 MPa is produced when the anchor structure was made through rescanning on thin wall with a hatch spacing of the anchor of 1.5 mm. AlSi10Mg was successfully deposited on AISI 316 L stainless steel using LDED. In addition, a macroscopic anchor was designed and manufactured using LDED to overcome the weak bond of the micro-anchor. To demonstrate the Al/Fe MMAM, a multi-material sine wave and QR code were developed.

Graphical Abstract