A comprehensive overview of metallic multi-material additive manufacturing using laser-based and Electron-based methods
Year: 2026
Type: article
Abstract: Multi-material additive manufacturing (MMAM) enables the fabrication of metallic components with spatially tailored properties by integrating dissimilar alloys within a single build. However, differences in thermophysical properties and solidification behaviour introduce interfacial instability, intermetallic compound (IMC) formation, and residual stress accumulation, limiting structural reliability. This review provides a process-focused synthesis of metallic multi-material systems farbicated using directed energy deposition (L-DED), laser powder bed fusion (L-PBF), and electron beam melting (EBM). The mechanisms governing crack formation and interfacial microstructure evolution are analysed from a manufacturing perspective. A process–structure–property framework is established to clarify how process-imposed thermal regimes, characterized by thermal gradient (G) and solidification rate (R), control diffusion depth, phase constitution, grain morphology and mechanical performance. Cross-technology comparisons demonstrate that interfacial stability is primarily dictated by thermal exposure and melt pool characteristics rather than material chemistry alone. Based on these insights, practical guidelines are proposed for material selection and compatibility assessment, fabrication strategy selection, and mechanical performance optimization. This review provides a manufacturing-oriented framework to support reliability and application-driven design in metallic MMAM.
Institutions: Swinburne University of Technology, Monash University
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $3,520
Funder: Australian Carbon Innovation
OpenAlex ID: W7160325152