Research Trends in the Directed Energy Deposition Method of Heterogeneous Materials

Abstract

Metal Additive Manufacturing (AM) or 3D printing garners attention for economically producing components with superior strength, durability, and corrosion resistance. The microstructure, influenced by factors like heat input, scanning speed, and layer thickness, shapes metal materials intricately in 3D printing.Unlike traditional manufacturing with separate fabrication and post-processing, Multi Materials AM (MM-AM) streamlines the construction of composite structures in a single step using a single machine. Although initial MM-AM, especially inpolymer 3D printing, was simpler, the shift to metal-based MM-AM presents challenges. The distinctive bonding style in MM-AM facilitates robust connections between different metals, minimizing stress concentration and simplifying the joining of diverse metals. Challenges like intermetallic compound formation, residual stress, and material-specific issues leading to cracks persist. Ongoing research focuses on metallurgy, process optimization,and computational simulation to overcome these hurdles. This review delves into current research trends in multi-material AM, identifying pathways for technological advancements. It discusses the application of Directed Energy Deposition (DED)in stacking austenitic and ferritic metals for nuclear power plant cooling system piping's gradient-form safe-ends. The study emphasizes advanced manufacturing techniques for developing functionally graded materials and dissimilar metal joints, highlighting the transformative potential of additive manufacturing across industries.