Abstract
Additive manufacturing (AM) of metallic alloys enables the production of components with complex geometric shapes. However, the component's size limitation and high manufacturing costs impede the use of this innovative technology in certain industries. This research presents a hybrid technique that integrates additive and subtractive technologies to provide economic benefits. The overall performance of the hybrid manufactured product is often influenced by the microstructural integrity of the interface between the substrate and the built part. The interfacial phenomena can be directly affected by heat transfer, element diffusion, dilution, solidification dynamics, and phase transformations, which are responsible for the significant changes in the alloy's microstructure. AlSi10Mg and AlSi7Mg powders were additively manufactured on an AA 6061 pre-machined substrate. The microstructural and mechanical integrity of these specimens is assessed through optical microscope, scanning electron microscopy (SEM), X-ray diffraction (XRD), tensile strength measurements, and microhardness testing.