Asymmetric interlocking and inclined remelting in laser powder bed fusion of horizontally joined AISI 316L–alumina parts
Year: 2025
Type: article
Abstract: Joining a metal, such as AISI 316L, to a ceramic with a lower coefficient of thermal expansion, such as alumina, presents challenges owing to the residual stress and stress concentration at the interface. For arbitrary geometries, a general mechanical model for suture interfaces is inspired by the wave shape. Among these, the triangular shape has demonstrated optimal performance in tensile tests but only moderate performance in three-point bending tests. This paper introduces a series of new asymmetric interlocking geometries designed to incorporate heterogeneous stress states and torsion during the deformation process. Experiments and crystal plasticity simulations using the finite-element and Rietveld methods were conducted to assess the results. The optimal asymmetric crank-like interlocking shape demonstrated high strength and ductility in tension, and it was nearly as effective as the triangular shape. This performance is attributed to significant bending moments, an anchor-like effect at the interface, and the emission of dislocations throughout the geometry. During bending, owing to the torsion distribution along the components, the crank shape exhibits a gradient in dislocation strengthening, a high distribution of hardness, and enhanced self-healing capabilities. Self-healing is facilitated by oxide fragmentation and crack filling during three-point bending, which is beneficial for cyclic deformation. Additionally, this paper introduces inclined remelting, a technique that can further mitigate common defects in metal–ceramic components and enhance the microhardness of the interface through the formation of a semi-solid flow.
Institution: Pusan National University
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,640
Award: G904442206
OpenAlex ID: W4414977502