Fig. 1. Aerospace applications of Cu/Ni heterogeneous metal systems. (a) GRCop-42(Cu-Cr-Nb)/HR-1(Fe-Ni-Cr) combustion chamber formed by LDED
[39]; (b) Cu-based/Ni-based injector formed by LPBF
[39]; (c) coupled thrust assembly formed by LDED
[39]; (d) injector structure and heterogeneous alloy connecting interface
[39]; (e) GRCop-42 combustion chamber formed by LPBF
[40]; (f) nickel-based cooling nozzle formed by BP-DED
[40]; (g) coupled bimetallic structure
[40]; (h) C18150/Inconel 625 rocket nozzle formed by SLM+LDED
[41]; (i) CuNi2SiCr/Inconel 625 rocket nozzle formed by LDED
[41]; (j) Cu-based/Ni-based bimetallic heat exchanger formed by SLM
[41]; (k) Cu-based/Ni-based bimetallic combustion chamber formed by SLM
[42] Fig. 2. Aerospace applications of Fe-based heterogeneous metal systems. (a) CW106C/1.2709 steel large caliber engine nozzle formed by
LPBF[43]; (b) 316L/aluminum-based bronze rocket engine nozzle formed byLDED[44]; (c) IN718/SS316L heat exchanger formed bySLM[45]; (d) CuCrZr/316L heat exchanger formed bySLM[46] Fig. 3. Aerospace applications of Ti-based heterogeneous metal systems. (a) Ti6Al4V/Nb coupled rocket nozzle component formed by LDED
[47]; (b) Ti6Al4V/Ti48Al2Cr2Nb turbine blade disk formed by LDED
[48] Fig. 4. LDED equipment for heterogeneous metal additive manufacturing. (a) Schematic of the working principle of LDED for heterogeneous metal additive manufacturing
[56]; (b) dual hopper LDED system
[57]; (c) LASERTEC 6600 additive-subtractive composite manufacturing equipment
[58]; (d) schematic of LMD static powder mixer equipment
[59] Fig. 5. LPBF equipment for heterogeneous metal additive manufacturing. (a) Dual feeder LPBF equipment
[60]; (b) zoning system for LPBF equipment
[61]; (c) ultrasonic powder spreading device for LPBF
[62]; (d) electrostatic powder spreading device for LPBF
[44]; (e) blade-ultrasonic powder spreading equipment for LPBF
[63] Fig. 6. Hybrid manufacturing cases. (a)(b)Schematic diagram of LMD-WAAM hybrid fabrication of IN625/SUS304L gradient material and macroscopic photographs of formed component
[68]; (c) 17-4 PH/AISI 316L component
formed by LPBF-WAAM[69]; (d) LPBF-LDED equipment, and QCr0.8 copper alloy/S06 stainless steel heterometal connection through the intermediate layer In718[70] Fig. 7. Factors affecting the quality of heterogeneous metal interfaces and solutions. (a1)(a2) Porosity/lack of fusion
[74] and related solutions; (b1)(b2) cracks
[75] and related solutions; (c1)(c2) harmful phases
[38] and related solutions; (d1)(d2) residual stresses
[76] and related solutions
Fig. 8. Heterogeneous metal joining strategies and cases. (a) Schematic diagrams of the four types of joining strategies
[77]; (b) LPBF direct joining of Cu10Sn/Ti6Al4V and its interface
[19]; (c) finger-crossed 316L/CuSn10 interfacial structure and samples formed by SLM
[81]; (d) bionic SS316L/IN625 interface structure formed by LDED
[82]; (e) Ti6Al4V/SS316 stainless steel heterometal connection through the intermediate layer Cu10Sn using SLM
[79]; (f) inconel 718/Ti64 heterometal connection through VC-Inconel 718-Ti64 combination bonding layer using LENS
[80]; (g) martensitic stainless steel/austenitic stainless steel connection through gradient layer using LENS
[78] Fig. 9. Influence of process parameters on the microstructure and properties of heterogeneous metal components. (a) Variation of the relative density of LMD-formed GH4169/K417G heterogeneous metal components with laser power
[76]; (b) LMD parameter optimization strategy and IN625/304L heterogeneous metal components prepared under the optimal parameters
[90]; (c) Ti6Al4V/AlSi10Mg heterogeneous metal interfaces formed by LPBF under different process parameters
[30]; (d) NiTi/CuSn10 heterogeneous metal interfaces formed by SLM under different process parameters
[12] Fig. 10. Development and application of online monitoring technology for LAM preparation of heterogeneous metals. (a)(b) Schematic diagram of the integrated high-speed imaging device of the LMD equipment and high-speed imaging pictures of the Cu deposition process
[99]; (c) LDED system with integrated monitoring and sensing device
[100]; (d)(e) schematic diagram of the in-situ X-ray imaging device integrated into the LPBF system and the photos of the Inconel 718/316L forming process captured under different processing parameters
[101]; (f) schematic diagram of integrated optical device for LDED systems
[102] Fig. 11. Development and application of simulation technique for LAM preparation of heterogeneous metals. (a) LDED modeling adaptive mesh and boundary conditions for thermal analysis
[103]; (b) machine learning flowchart for SLM parameter optimization
[104]; (c) simulation of powder bed temperature distribution with different gradient IN718 components during LPBF manufacturing of IN718/Ti6Al4V
[105]; (d) simulation of deformation and stress distribution in LDED manufacturing of Cu/SS304L
[83] Fig. 12. Effect of pretreatment on microstructure and properties of heterogeneous metal components. (a)‒(c) Preheating process of LDED in the manufacture of Inconel 625/Ti6Al4V gradient materials and the comparison of the effect of forming samples with or without preheating
[110]; (d)(e) comparison of microstructures of CuBe/H13 formed by LMD with or without preheating
[111]; (f)‒(h) hardness, relative density, and microstructure of GH4169/K417G samples formed by LMD with or without preheating
[76] Fig. 13. Effect of post-treatment on microstructure and properties of heterogeneous metal components. (a)(b) The effect of heat treatment on the microstructure and mechanical properties of LPBF-formed 316L/Inconel 718 components
[112]; (c) the effect of heat treatment on the hardness of LPBF-formed maraging steel/Co-Cr-Mo alloy components
[113]; (d) the effect of hot isostatic pressing on the microstructure and hardness of LPBF-formed Ti/Ti64 components
[114] Material system | Material property | Application | Typical heterogeneous metal system |
---|
Cu/Ni | Thermal conductivity/heat resistance/ high strength | Aerospace thrust components/integrated circuit | Inconel 718/GRCop84[11] NiTi/CuSn10[12] Inconel 718/ CuCr0.8[13] | Cu/Fe | High stiffness/electrical conductivity/thermal conductivity/wear resistance | Nuclear industry/power generation industry/automobile industry | 316L/CuSn10[14] 316L/C52400[15] 316L/CuCrZr[16] | Cu/Ti | Heat resistance/high specific strength | Aerospace heat exchanger | Ti6Al4V/Cu[17] Ti6Al4V/CuNi2SiCr[18] Cu10Sn/Ti6Al4V[19] | Cu/Al | Electrical/thermal conductivity/low density | Energy conduction/cooling device/solar collector | AlSi10Mg/C18400[20] | Ni/Fe | High strength/corrosion resistance/oxidation resistance | Gas turbine/power generation equipment/heat exchanger | 316 L/Inconel 718[21] 316L/Inconel 625[22] SS420/Inconel 718[23] | Ni/Ti | Biocompatibility/wear resistance/high specific strength/heat resistance | Aerospace thermal protection system/orthopedic implants | Inconel 718/Ti6Al4V[24] TC4/Inconel 625[25] NiTi/Ti6Al4V[26] | Fe/Ti | High specific strength/corrosion resistance | Aerospace engines/load-bearing components | Ti6Al4V/316L[27] | Fe/Al | High strength/corrosion resistance/lightweight | Automotive manufacturing/aerospace hydraulic systems/space launch systems | 316L/AlSi10Mg[28] 316L/Al[29] | Ti/Al | Lightweight/ductility and malleability/high strength | Aerospace and automotive structural component | Ti6Al4V/AlSi10Mg[30] AA2024/Ti6Al4V[31] Ti6Al4V/Al12Si[32] | Co/Ti | Biocompatibility/high strength | Medical implant | CoCrMo/Ti6Al4V[33] | Co/Ni | Corrosion resistance/high strength | Nuclear industry/petrochemical industry | CoCrMo/Inconel 718[34] CoCrMo/Inconel 625[35] | Co/Fe | Heat resistance/wear resistance/high toughness | Machining tools and mold manufacturing | SS316L/CoCrMo[36] | W/Cu | Electrical/thermal conductivity/resistance to plasma radiation | Integrated circuit radiator/electrode/nuclear industry | Cu10Sn/W[37] | W/Fe | Ductility and malleability/resistance to plasma radiation/high strength | Nuclear industry | W/316L[38] |
|
Table 1. Typical heterogeneous metal systems and their properties and applications
Technique | Advantage | Limitation | Solution |
---|
LPBF | 1) High forming accuracy 2) Higher quality of interface bonding | 1) Lower processing efficiency[50] 2) Difficult to control the precise distribution of powder[51] 3) Cross-contamination issue with powders[52] 4) Intra-layer heterogeneous material composition connectivity is limited[53] | 1) Hybrid manufacturing 2) Development of new powder spreading device 3) Developing multi-beam and large-area equipment 4) Upgrade of powder recycling unit | LDED | 1) High degree of processing freedom 2) Wide selection of raw materials 3) High processing efficiency 4) Good flexibility in powder feeding | 1) Lower forming accuracy[54] 2) Intra-layer heterogeneous material composition connectivity is limited[55] | 1) Integration of additive and subtractive manufacturing processes 2) Hybrid manufacturing 3) Improvement of powder feeding and mixing device |
|
Table 2. Advantages, limitations, and solutions of traditional LPBF and LDED techniques in heterogeneous metal manufacturing
Equipment Optimization Strategy | Technique | Material | Advantage/effect | Reference |
---|
Blade-based dual powder recoater | LPBF | Ni/Ti | Cracks and brittle phases exist at the interfacial joints; such technique is difficult to realize the deposition of heterogeneous materials in the same layer and are limited in the applicable material systems, with poor forming quality | [60] | Ultrasonic assisted powder spreading | LPBF | W/316L | Heterogeneous metals are well bonded; such technique has high powder layup accuracy and design freedom, but is very inefficient | [65] | Electrostatic powder spreading | LPBF | | Such technique has a high degree of design freedom and powder feeding efficiency, but is prone to powder layer contamination problems | [63] | Blade + ultrasonic hybrid powder spreading | LPBF | 316L/Cu10Sn | Good metallurgical bonding of heterogeneous metals; such technique combines high precision and efficiency | [66] | Dual powder feeder | LDED | AISI 316L/ AISI H13 | Individual transportation of dissimilar powders and successful bonding of heterogeneous metals are realized | [57] | Static mixing device | LDED | 316L/Cu | Improved powder mixing homogeneity for the preparation of functional gradient layers | [59] | Integration of additive and subtractive manufacturing | LDED | | Improved efficiency and precision of heterogeneous metal forming | [58] | Equipment improvement | LPBF | AISI 316L/ Ni-based high-temperature alloy | Preparation of intra-layer bimetallic samples realized | [61] | LPBF | AISI 316L-18Ni (300) | Preparation of intra-layer bimetallic samples realized | [67] |
|
Table 3. Development and advantages of heterogeneous metal additive manufacturing equipment for LPBF and LDED
Technology integration strategy | Material | Advantage/effect | Reference |
---|
LMD-WAAM | SUS304L/IN625 | Combines the high efficiency of WAAM with the flexibility of LMD/Good metallurgical bonding of heterogeneous materials with high mechanical properties | [68] | LPBF-WAAM | 17-4 PH/ AISI 316L | Hybrid manufacturing facilitates the preparation of complex and large cross-section structures/Heterogeneous interfaces are well bonded and have high mechanical properties | [69] | LPBF-LDED | QCr0.8/In718/S06 stainless steel | Combines the high precision of LPBF with the flexibility of LDED/Heterogeneous interfaces are well bonded and defect-free | [70] | WAAM-LDED | ER70S6/Inconel 625 | Combines the high efficiency of WAAM with the flexibility of LDED/Heterogeneous interfaces are well bonded and have high mechanical properties | [71] | LPBF-LDED | SS316L/IN625 | Integration of LPBF for high forming accuracy and LDED for fast deposition/Good heterogeneous interface bonding | [72] | SLM-CS(cold spraying) | Al/Ti6Al4V | CS avoids defects associated with the melting process, SLM offers high forming accuracy/Better bonding at heterogeneous interfaces, and inhibits the generation of brittle phases | [73] |
|
Table 4. Hybrid manufacturing processes for heterogeneous metals and their advantages
Connection strategy | Material | Technique | Effect | Reference |
---|
Direct connection | Cu10Sn/Ti6Al4V | LPBF | Interface delamination, bonding failure | [19] | Cu/SS 304L | LDED | High residual stresses at the interface, poor bonding effect | [83] | Gradient layer connection | Martensitic stainless steel/ Austenitic stainless steel | LENS | Good metallurgical bonding, improved mechanical properties | [78] | 316L/IN718 | LPBF | Good metallurgical bonding, good mechanical properties | [84] | AISI 316L/Fe35Mn | LPBF | Good metallurgical bonding, mechanical properties vary with composition gradation | [85] | 316L/Inconel 625 | LDED | Good metallurgical bonding, uniform microstructure at the interface | [22] | Ti6Al4V/NiTi | LDED | Defect-free interface structure and good mechanical properties | [86] | Intermediate layer connection | 316L/HOVADUR K220/ Ti-6Al-4V | SLM | Good metallurgical bonding | [79] | Cu10Sn/316L/W | LPBF | Good metallurgical bonding | [37] | TC4/Cu/IN718 | LDED | Inhibits the creation of defects, good interfacial bonding | [87] | IN625/Cu/TC4 | LDED | Good metallurgical bonding | [88] | Ti6Al4V/Cu/Al-Cu-Mg | LPBF | Good metallurgical bonding, no visible defects | [89] | Compositional bond layer connection | Inconel 718/VC mixture/ Ti6Al4V | LENS | No cracks in the interface, successful bonding | [80] | Interface shape design | 316L/CuSn10 | SLM | Good metallurgical bonding, improved mechanical properties | [81] | 316L/IN625 | LDED | Good bonding, improved mechanical properties | [82] |
|
Table 5. Joining strategies and forming effects of heterogeneous metals
Material | Technique | Laser power /W | Scanning speed /(mm/s) | Scanning space / overlap rate | Layer thickness /μm | Powder feeding rate | Reference |
---|
Ti6Al4V/ AlSi10Mg | LPBF | 310 | 2200 | 0.12 | 30 | | [30] | Ti6Al4V/Inconel 625 | LMD | 1500 | 600 | 50% | | 6.0 g/min | [91] | Ti6Al4V/Ti48Al2Cr2Nb | LMD | 1900 | 7 | | | 4.96 g/min | [92] | Ti6Al4V/NiTi | SLM | 90 | 600 | 0.09 | 30 | | [26] | Ti6Al4V/IN718 | SLM | 300 | 700 | 0.05 | 50 | | [93] | 316L/Co-Cr-Mo | LENS | 800 | 6.67 | | | 6.0 g/min | [36] | 316L/IN718 | LPBF | 95 | 500 | 0.084 | 25 | | [84] | 316L/Hastelloy X | LPBF | 95 | 200 | 0.045 | 30 | | [94] | 316L/IN718 | LDED | 1000 | 7 | 50% | | 1 r/min | [95] | 316L/TC4 | LMD | 1400 | 6 | 50% | | 2.5 r/min | [96] | Inconel 718/316L | LPBF | 300 | 900 | 0.08 | 30 | | [97] | Inconel 718/CoCrMo | LPBF | 225 | 700 | | | | [34] | Inconel 718/SS420 | LDED | 900 | 15 | | | | [23] | Inconel 625/316L | LENS | 335 | 18 | | | 3.8 g/min | [98] | Inconel 625/304L | LMD | 600 | 10 | 50% | | 8 g/min | [90] | GH4169/K417G | LMD | 528 | 4 | 40% | | 18.9 mm3/s | [76] | NiTi/CuSn10 | SLM | 120 | 250 | 0.08 | 30 | | [12] |
|
Table 6. Optimization/processing parameters for classical heterogeneous material
Monitor signal | Material | Technique | Monitoring device | Advantage/effect | Reference |
---|
Optical signal | Cu, Al, Steel/Ti alloy | LMD | High-speed camera (optical imaging) | Real-time monitoring of the melt pool dynamics, powder status and solidification characteristics, which can be adjusted accordingly | [99] | Ti/Nb | LDED | Spectrum collection device | High precision monitoring of chemical composition/process status/serious defects | [100] | Inconel 718/316L | LPBF | High-speed X-ray imaging device | It can realize real-time monitoring of microstructure and defect evolution as well as thermal behavior of molten pool, and can adjust the process accordingly | [101] | 316 L/AlSi10Mg | LMD | Collimating lens + optical fiber (spectral collection) | The relationship of spectral intensity-gradient composition evolution can be established to realize composition control in manufacturing process | [102] | Acoustic signal | Ti/Nb | LDED | Microphones | For laser-material interaction monitoring with high acquisition rates but poor monitoring accuracy | [100] |
|
Table 7. Monitoring techniques for laser additive manufacturing of heterogeneous metals
Forecast content | Material | Technique | Model/method | Advantage/effect | Reference |
---|
Thermal behavior + residual stress | IN718/Ti6Al4V | LDED | Sequential coupled thermo-mechanical model | The predicted results are qualitatively in agreement with the experimental results / thermal response, solidification behavior and residual stress sources can be predicted | [103] | Cu/SS304L | LDED | Thermo-mechanical Finite Element Modeling | Accurate prediction of temperature and residual stress distribution can be achieved | [83] | IN718/Cu10Sn | LPBF | Mesoscopic modeling based on the VOF method | The behavior of molten pool and solidification trajectory can be predicted | [105] | 316L/Inconel 718 | LDED | Finite element simulation | High simulation accuracy for effective analysis of thermal behavior during the forming process | [106] | TC4/TC11 | LMD | Finite element simulation | The temperature field trend, period and peak temperature calculated by the model are in good agreement with the experiment, which verifies the validity of the model | [107] | Process parameters | AlSi10Mg/316L | SLM | Gaussian process regression (MO-GPR) modeling | Process parameter optimization can be significantly shortened | [104] | Fe/Ni | LDED | Mathematical models constructed based on MATLAB | Correlating laser process parameters to composition states | [108] | 316L/Cu | SLM | Multivariate Gaussian process model | Can be used for parameter prediction under different gradient composition changes | [109] |
|
Table 8. Simulation and modeling techniques for laser additive manufacturing of heterogeneous metals
Processing method | Material | Technique | Effect | Reference |
---|
Substrate preheating | Inconel 625/Ti6Al4V | LDED | Optimized microstructure and improved forming quality | [110] | CuBe/H13 | LMD | Inhibit the formation of defects and improve mechanical properties | [111] | GH4169/K417G | LMD | Reduced residual stresses and increased relative density of samples | [76] | Heat treatment | 316L/Inconel 718 | LPBF | Modulation of microstructure distribution to improve mechanical properties | [112] | Maraging steel/Co-Cr-Mo | LPBF | Elimination of residual stresses, improvement of interface quality and toughness | [113] | In718/316L | LDED | The strength and toughness of the components are improved | [115] | Hot isostatic pressure | Ti/Ti64 | LPBF | Elimination of residual stresses and improvement of mechanical properties | [114] |
|
Table 9. Pre- and post-treatments for laser additive manufacturing of heterogeneous metals