Abstract:

Additive manufacturing offers unique opportunities to produce multi-material metallic components with spatially tailored proper-ties, yet the mechanical response of architecturally distinct metal interfaces remains underexplored. In this study, the influence of volume fraction of the two additively manufactured dissimilar metals adjoined together on the tensile behavior is studied. Stain-less steel 316L (SS) and Inconel 718 (IN) were combined within a single build using laser direct energy deposition, with an interface oriented perpendicular to the applied loading direction. To isolate the effect of material proportion, samples were prepared with var-ying SS316/IN718 volumetric percentages: 100/0, 70/30, 50/50, 30/70, and 0/100. Mechanical evaluation combined uniaxial ten-sile tests, digital image correlation for full-field strain analysis, and fractographic examination whenever required. Across all hybrid configurations, failure consistently initiated and propagated within the SS portion, irrespective of the IN content. Furthermore, the overall tensile response, including yield strength, ultimate ten-sile strength, and ductility, was similar to that of monolithic SS ra-ther than IN, even at higher IN volume fractions. These findings indicate that, when the interface is oriented perpendicular to the loading direction, the overall tensile response is dictated by the softer constituent. The limited load-sharing contribution of IN un-der these conditions highlights the critical role of interface orien-tation and load path in multi-material systems. Collectively, these results provide guidance for the rational design of additively man-ufactured dissimilar metal structures and reinforce the need for strategic architectural design to achieve desired mechanical out-comes.

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Dr. Amany Khaled Sayed