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<p>Bimetallic materials gained significant attention in the rapidly evolving manufacturing industry due to their ability to combine the desired property of two distinct metals for site-specific applications, enabling the fabrication of parts with superior properties including high specific strength and thermal conductivity at elevated temperatures together with resistance to creep, corrosion, and oxidation. This can considerably promote materials selection for designing a component with a particular industrial application by fabricating a bimetallic material from the combination of two engineering alloys such as nickel-based superalloys, titanium alloys, copper alloys, aluminum alloys and stainless steels. Bimetallic materials are employed in numerous fields including automotive, aerospace, energy, transportation, petrochemical and medical industries, signifying the versatility they provide for critical industrial applications. In addition to conventional methods for fabricating bimetallic materials, additive manufacturing (AM) techniques offer the ability to produce more complex geometries with greater dimensional precision than traditional joining approaches, making them an increasingly attractive alternative. AM can be divided into two main categories, namely fusion-based processes and solid-state processes. Fusion-based AM processes offer extremely high in-plane resolutions, producing features as small as sub-25&#xa0;µm with high precision. These methods, however, form columnar structures, resulting in notable anisotropy. In addition, they are prone to thermal residual stresses and unfavorable fabrication-induced porosity. Solid-state AM processes, on the other hand, end up having refined equiaxed microstructure and isotropic properties together with a nearly nonporous structure without solidification-induced defects such as solidification cracking. Nevertheless, these methods are not fit for high in-plane resolution as they can fabricate feature sizes on the order of 1&#xa0;mm or greater, and high-aspect-ratio components can cause mechanical instability such as buckling during their fabrication. Furthermore, their surface finish and ability to fabricate complex geometries is usually inferior compared to fusion-based AM processes. Taking the pros and cons of both AM categories into account, it is worth reviewing the available literature for their potential in bimetallic structures fabrication and gain a better understanding of process-structure-defects-properties relationship for the bimetallic systems. This review may provide insight into future research directions for this fast-growing field and can present a perspective on the utilization of AM techniques in bimetallic materials production.</p> Graphical Abstract <p></p>

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A review of the microstructures, defects, and mechanical properties of the additively manufactured bimetallic materials

  • 期刊论文

  • 发表日期：

    2026年2月23日

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  • Amirreza Khodabakhshi,
  • Keivan Davami,
  • Sadie Beck,
  • A. B. M. Tahidul Haque

摘要

Bimetallic materials gained significant attention in the rapidly evolving manufacturing industry due to their ability to combine the desired property of two distinct metals for site-specific applications, enabling the fabrication of parts with superior properties including high specific strength and thermal conductivity at elevated temperatures together with resistance to creep, corrosion, and oxidation. This can considerably promote materials selection for designing a component with a particular industrial application by fabricating a bimetallic material from the combination of two engineering alloys such as nickel-based superalloys, titanium alloys, copper alloys, aluminum alloys and stainless steels. Bimetallic materials are employed in numerous fields including automotive, aerospace, energy, transportation, petrochemical and medical industries, signifying the versatility they provide for critical industrial applications. In addition to conventional methods for fabricating bimetallic materials, additive manufacturing (AM) techniques offer the ability to produce more complex geometries with greater dimensional precision than traditional joining approaches, making them an increasingly attractive alternative. AM can be divided into two main categories, namely fusion-based processes and solid-state processes. Fusion-based AM processes offer extremely high in-plane resolutions, producing features as small as sub-25 µm with high precision. These methods, however, form columnar structures, resulting in notable anisotropy. In addition, they are prone to thermal residual stresses and unfavorable fabrication-induced porosity. Solid-state AM processes, on the other hand, end up having refined equiaxed microstructure and isotropic properties together with a nearly nonporous structure without solidification-induced defects such as solidification cracking. Nevertheless, these methods are not fit for high in-plane resolution as they can fabricate feature sizes on the order of 1 mm or greater, and high-aspect-ratio components can cause mechanical instability such as buckling during their fabrication. Furthermore, their surface finish and ability to fabricate complex geometries is usually inferior compared to fusion-based AM processes. Taking the pros and cons of both AM categories into account, it is worth reviewing the available literature for their potential in bimetallic structures fabrication and gain a better understanding of process-structure-defects-properties relationship for the bimetallic systems. This review may provide insight into future research directions for this fast-growing field and can present a perspective on the utilization of AM techniques in bimetallic materials production.

Graphical Abstract