Work

Bonding SS316L and IN625 through laser powder bed fusion and directed energy deposition: a comparative tensile analysis

Year: 2025

Type: article

Abstract: Directed Energy Deposition (DED) was used to deposit Inconel 625 (IN625) onto 316L stainless steel (SS316L) substrates fabricated by Laser Powder Bed Fusion. Tensile properties of the resulting multi-material specimens were compared to those of the individual alloys. Two bonding approaches were evaluated: a direct transition and a 50/50 intermediate layer formed by blending equal parts of each alloy during deposition. The multi-material specimens demonstrated higher yield strength than the single alloys. However, samples with the 50/50 transition exhibited brittle failure at the joint, whereas the direct transition behaved more ductile. Scanning Electron Microscopy revealed microcracks at the interface of the 50/50 transition, and Energy Dispersive Spectroscopy detected aluminum oxide particles in the DED-IN625 samples. These results underscore the importance of transition design in multi-material components and provide guidance for optimizing mechanical performance in demanding applications such as in extreme conditions, particularly where structural integrity and high-performance bonding are critical.

Source: npj Advanced Manufacturing

DOI: 10.1038/s44334-025-00044-x

Authors: Christopher J. Bettencourt, Nadia Kouraytem

Institution: Utah State University

Language: English

Topic: Additive Manufacturing Materials and Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: hybrid

Estimated APC paid: $2,490