Materials Today: Proceedings xxx (xxxx) xxx

Contents lists available at ScienceDirect

Materials Today: Proceedings

journal homepage: www.elsevier.com/locate/matpr

A review on additive manufacturing of SS-Ni multi-material fabrication

Rupendra Singh Tanwar, Suyog Jhavar ⇑
School of Mechanical Engineering, VIT-AP University, Inavolu, Beside AP Secretariat Amaravati, Andhra Pradesh 522237, India

a r t i c l e i n f o a b s t r a c t

Article history: Additive manufacturing (AM) is an emerging technology used to fabricate complex and near net shape
Available online xxxx components with minimum tooling and material wastage. This technology has found its application in
biomedical, aerospace, automobile and structural elements. Multi material additive manufacturing
Keywords: (MMAM) process is able to manufacture components built with a combination of different materials like
Multi-material AM metals, ceramics, and reinforced materials to achieve the desired properties at a specific location. Many
LPBF multi-material combinations have been fabricated through MMAM such as Al-Fe, Al-Cu, SS-Ni, Ni-Ti, Ti-
WAAM
SS, diamond-W-Cu etc. The most common combination among these discussed materials are SS-Ni multi-
DED
SS/Ni multi-material
material for its wide range of applications in gas turbine parts, energy industry, petrochemical industry,
Microstructure marine industry, nuclear fission reactors, aerospace structure and aerospace engines. The processing of
Mechanical properties SS-Ni multi-material using LPBF, DED and WAAM has been found to provide superior properties such
as high strength at extreme temperature environment, corrosion resistance, oxidation resistance, higher
toughness at low cost when compared with conventional manufacturing methods thereby, motivating
the present review on SS-Ni multi-material AM. This review aims to summarize the various methods
used for the fabrication of SS-Ni multi-material AM, different combination strategies and its effect on
the quality of fabrication, their microstructure variations, property enhancement, challenges and
applications.
Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the International Conference on Advances in Smart
Materials, Chemical & Biochemical Engineering.

1. Introduction method classified based on binding mechanism, type of feed stock,

The manufacturing world is ever-changing, emergence of state-
of-art of manufacturing technology is most significant driver for
this continuous change. Combined with other trends such as per-
sonalization, servitisation, and prosumption, the dawn of additive
manufacturing as on demand manufacturing process is leading
manufacturer to emend where and how performed manufacturing
activities. Additive manufacturing (AM), is a process of fabricating
3-dimensional object of intricate shapes such as colling channels
with minimum tooling at lowest material waste, successive layers
of materials deposited to one over other followed by the CAD
model [1,2]. AM has a potential to replace all conventional manu-
facturing methods, AM process reduce the need of tooling, gives
design flexibility and customization of product as compared to
conventional manufacturing methods [3]. Last decade grabs a lot
of attention towards AM because of its intrinsic advantages such
as less processing time and high material utilization [4]. AM
⇑ Corresponding author.
and nature of heat source. In metal AM feedstock is either in the
form of powder [5] or wire [6] is completely melted by heat source
(laser or electron beam) and transformed into net near shape solid
using layer by layer approach [7]. The most eminent metal AM pro-
cesses are powder bed fusion (PBF) [8], Laser Direct Energy Depo-
sition (LDMD) [9], wire arc additive manufacturing (WAAM) [6],
laser direct metal deposition (LMD) [10], laser engineered net
shaping (LENS) [11]. Despite different AM methods, all AM method
follows same approach: it starts with 3D CAD model, it is created
on computer, created model is sliced into thin layers generally
layer thickness from 20 lm
1 mm [12].
Each metal AM method has its strength and shortcomings, such
as laser or electron beam powder bed fusion (PBF) can achieve
high-geometric accuracy fabrication depends on their high energy
densities, with this it has some limitations such as expensive
equipment, low production efficiency, and narrow range of pro-
cessing parameters. Moreover, high reflective material, recycling
of powder, health hazards also limit the use of laser PBF, high
energy density also a serious cause of defects such as pores, cracks,

https://doi.org/10.1016/j.matpr.2023.03.044
2214-7853/Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the International Conference on Advances in Smart Materials, Chemical & Biochemical Engineering.

Please cite this article as: R. Singh Tanwar and S. Jhavar, A review on additive manufacturing of SS-Ni multi-material fabrication, Materials Today: Proceed-
ings, https://doi.org/10.1016/j.matpr.2023.03.044
R. Singh Tanwar and S. Jhavar
harmful interface reactions, and ceramic particle dissolution. As
compared to PBF, wire arc additive manufacturing (WAAM) based
on arc welding, low-cost technology, which offers high deposition
rate, good adoptability to process, materials, and environment and
high handling mobility. Therefore, WAAM is suitable for manufac-
turing large components at low cost, for moderately complex
geometries [6,13] with this it has also limitations such as in-situ
product has less surface roughness, heat treatment required,
porosity, oxidation.
The pure metal gives specified value of mechanical properties, it
is modified or improved by alloying of pure metals with other met-
als or non-metals. Fig. 1 shows comparison of pure metal, conven-
tional alloying, and multi-metal structure. Now a days engineering
applications urge metallic material with improved, customized,
and site-specific properties that alloy or pure metal could not sat-
isfy [14]. With the development of engineering and societal needs,
single-material product cannot fulfil the customize requirements.
Customized product fabricated using multiple materials has a bet-
ter application possibility due to combination of excellent proper-
ties of different materials. Multi-material AM (MMAM) has a
capable to deal with wide range of materials and fabricate multi-
material component. AM method can tailor the compositions at
user specified locations, it alters the properties such as strength,
hardness, corrosion resistance, wear resistance in a single compo-
nent at a desired position and desired amount [13].
Bimetallic structure, combining two distinct metals and func-
tionally graded material (FGM), varying in proportion of materials
[15] it varies microstructure, mechanical properties with position
there have many multi-metal combinations fabricated through
various AM processes such as Al-Fe [16], Al-Cu [17], SS-Ni [18],
Ni-Ti [19], Ti-SS [20], diamond-W-Cu [21]. Ni based alloys has a
wide range of applications due to its excellent properties such as
high toughness, high hardness, and high hot strength. With this
many other properties like can be used for wide range of temper-
ature, high corrosion resistance, at elevated temperature shows
phase stability, and better creep resistance. As a result of that
broad range of applications particularly in powder industries,
defence, space shuttle engines, nuclear, and aerospace [22]
whereas Ni based alloys has high cost. SS based alloys also has a
wide range of applications because of its unique properties like
strength, hardness, toughness, excellent weldability. Hence finds
many applications in distillation industry, phosphoric acid indus-
Fig. 1. Methods of material preparation.
2
Materials Today: Proceedings xxx (xxxx) xxx
try, automotive, aerospace, offshore industries, nuclear, supportive,
and structural industry [18]. SS based alloys has high affinity with
adjacent substance because of high solubility of principal elements
(Fe, Cr and Ni) even towards the precipitate elements [23] whereas
steel-based alloys available at low cost. Using the advantage of
both material and overcome the shortcoming by fabricating
bimetallic or FGM components. Fabricating Stainless steel and Ni
based alloys bimetallic or FGM component gives high mechanical
strength, excellent corrosion resistance at elevated temperature
[24]. SS-Ni alloys are two widely used metals for bimetallic or
FGM structures in power generation, aerospace, chemical, petro-
chemical, and marine applications [25,26].
This paper discusses different metal AM processes such as pow-
der bed fusion, direct energy deposition, and wire arc additive
manufacturing used to fabricate SS-Ni multi-materials, applica-
tions, microstructure. All the above method modified form of
multi-metal additive fabrication. Challenges occurs during the
multi-material fabrication such as optimization of parameters to
fabricate defect free component. This review gives the insight of
microstructure and mechanical properties such as tensile strength,
hardness, wear behaviour substrate preheat and addition of carbon
fibre and other material elements added in SS-Ni to improve prop-
erties of SS-Ni AM components.
2. Overview of multi-metal additive manufacturing (MMAM)
methods
AM is a process of fabricating 3D object by joining of materials
using layer-by-layer approach. It is opposite to subtractive manu-
facturing methods [27]. Fig. 2 (a-c) represents various methods
used for multi-mateiral AM. For fabricating SS-Ni multi-material
using different AM method such as LAM-DED [5,10], Laser Engi-
neered Net Shaping (LENS) [28], PBF [8], WAAM [29]. Powder
Bed Fusion (PBF) is also called selective laser melting, in this
method focused energy heat source (laser or electron) is used to
melt powder which is on a substrate. For manipulating position
of heat source, a system of lens and mirrors are used. Power, scan
speed, scan strategy etc. play important role in the final fabricated
component. For multi-material fabrication use two powder supply
chambers, two excess powder collecting pots, with one roller or
soft powder distribution coater blade which spread the powder
on a build surface or bed. The powder is taken from the supply
R. Singh Tanwar and S. Jhavar
Fig. 2. Multi-metal AM methods (a) powder DED, (b) twin wire arc AM and (c) powder bed fusion.
chamber and spread on the substrate using coater, after melting of
powder by beam, un-melted powder collect in a collecting pot by
coater and next metal powder is spread on a substrate and the
whole process repeat itself until the whole component not fabri-
cated. After completing each layer fabrication powder bed lowers
and powder supply bed moves up. Generally, argon gas used for
shielding in case of laser heat source and vacuum is maintained
in case of electron beam heat source [8].
In DED process the FGM and bimetallic component fabricated
using two or more than two powders, the gas atomized alloy pow-
der with some specific size in range of 45 – 106 lm used as a feed-
stock material. The DED process accomplished CNC platform
combines with laser or electron beam and two or more powder
feeders a schematic diagram as shown in Fig. 2(a) [26]. Laser
power, scan speed, hatch distance, hatch rotation angle, contact
tip to work-piece distance (CTWD) and powder feed rate also
important during DED fabrication. The mixing of two powder has
been done in a mixing chamber or supplied individually [30,31].
Powders blown from feeder counts individually using argon gas
with a specified feed rate. Laser and powder feeding are co-axial,
as powder blown on a surface and melted simultaneously it form
a layer. If it is FGM component the certain volume fraction of
one material powder increases and other material powder
decreases after some specified number of layers [32]. In case of
3
Materials Today: Proceedings xxx (xxxx) xxx
bimetallic component, first blown one material powder for a cer-
tain height, after that next material is supplied [20].
WAAM is also a part of DED processes, WAAM is budding
technology it uses electric arc as a heat source for fabricating
metallic component, WAAM got extensive attention from indus-
trialist and experts due to its unique qualities such as high depo-
sition efficiency at low cost, flexibility, unlimited deposition
capacity, environmental friendliness [33]. The electric arc gener-
ated by different arc welding methods such as gas tungsten arc
welding (GTAW), gas metal arc welding (GMAW), plasma arc
welding (PAW) each one has distinct set of advantages and limi-
tations with respect to productivity, material properties and res-
olution [34]. Wire feed speed, voltage, current, travel speed, gas
flow rate, and nozzle-to-work distance are important parameters
for defect free fabrication [35]. multi-material component fabri-
cated using two or more than two wires called twin wire
(T-WAAM) a schematic diagram as shown in Fig. 2(b) [36].
Initially root-pass and inter-pass layers produced using material
A wire, after certain layers of welding passes, material B
deposited on it to fabricate bimetallic component. During this
deposition process generally, argon is supplied as a shielding
gas [37]. Table 1 presents a brief overview of different AM
methods used for fabrication of SS-Ni combinations, their pre
and post processing used in various literatures.
R. Singh Tanwar and S. Jhavar
Table 1
Various alloy combinations, AM methods and post processing.
AM methods Different SS-Ni Combination
PBF or SLM SS316L/IN718
Liquid dispersed metal PBF SS316L/IN625
Laser DED SS316L/IN718
SS316L/IN625
SS316L/Carbon fibre/IN718
SS420/IN718
SS304L/IN625
SS316L/Ni-Cr-B-Si
SS304L/No-20Cr
AISI1045/IN718
Laser DED + Thermal milling SS316L/IN718
LENS SS316L/IN625
WAAM SS321/IN625
SS316L/IN625
SS316L/Nickel Aluminium Bronze(NAB)
SS316L/IN625
RMD 248/ ERNiCr-3
Electron Beam Melting 316L/IN718
3D plasma metal deposition SS316L/Ni80-20 and SS316L/Ni 625
3. Microstructure and mechanical properties of SS-Ni additively
manufactured components
In this section, discuss about the microstructure characteriza-
tion and evaluation of properties of SS-Ni multi-material part fab-
ricated through various additive manufacturing methods such as
Laser PBF, Laser DED, electron beam PBF, laser engineered net
shaping (LENS), Wire arc additive manufacturing (WAAM). The
microstructure characterization has been done by scanning-
electron microscopy (SEM), optical microscopy, X-ray diffraction
(XRD), electron back scattered diffraction (EBSD) etc. mechanical
properties such as strength, hardness, fracture toughness, friction
wear behaviour evaluated by tensile testing, microhardness, tri-
bometer etc.
3.1. Microstructural characterization
For the fabrication of SS-Ni multi-material, different additive
manufacturing methods such as LPBF, SLM, EBM, LMD, WAAM,
LENS etc. used, [10,38] fabricated functionally graded material
(FGM) of varying the percentage of either SS and Ni alloy and
Bimetallic components on metal over the other one. [38,39] uses
Laser DED for the fabrication of SS420 and IN718, along the build
direction found equiaxed grains in SS420 whereas IN718 shows
columnar grains with dendrite structure. In mixed portion of
SS420 and In718 shows has carbide and lave phases, carbide
phases formed due to presence of reactive metallic element such
as Mo and Nb. [40] uses horizontal and vertical strategies for the
fabrication of SS-Ni FGM part researcher found in both cases cellu-
lar, and columnar dendrite structure found for horizontal gradient
sample and columnar and equiaxed for vertical gradient this differ-
ent structure because of colling rate and temperature gradient.
Whereas [25,36] suggested during fabrication of bimetallic compo-
nent using WAAM, at the interface Cr is homogenously distributed
at both metal side, while Ni, Nb and Mo more distributed towards
IN625 and Fe distributed more towards SS316L side. Using gradual
variation, no secondary phases such as metallic carbide and d-
phase found. In other hand [41,42] uses SLM for the fabrication
of SS-Ni multi-material, researcher found that there is no carbide
and lave phases observed. [43,44] founds tempered martensite,
carbides, tempered sorbite and retained austenite. The variation
in microstructure observed because of variation in welding param-
4
Materials Today: Proceedings xxx (xxxx) xxx
Pre or Post processing Author
— [42,56,60]
— [8]
— [24,26,40,46,51,52,53,58]
— [28,47,54]
Laser Synchronous preheating [10]
— [49]
— [39]
— [57]
— [5]
— [32]
— [26]
— [50]
— [59]
— [44]
[36]
— [18]
— [25]
— [43]
— [55]
— [45]
eters. [45] fabricated SS316L and Ni based alloy using 3D plasma
metal deposition, on the macroscopic scale, lack of fusion observed
at the SS316L side whereas cracks at Ni625 side [46] secondary
dendrite arm spacing is observed in mixed portion of the sample
and it depends on the laser power and metal powder feed rate in
laser DED [47] researcher uses two different strategy type-1
(In625 on SS316L) gradual composition it results epitaxial growth
due to SS316L has lower density and lower viscosity increases the
remelting of SS316L to flow upward and mix with In625 whereas
in type-2 (SS316L on In625) abrupt composition results no epitax-
ial growth observed due contrary property of In625 with respect to
SS316L i.e., no mixing occurs. Researcher [32] fabricated NiCr and
SS316L part using LDED, researcher found that hardness is the
function of NiCr percentage in a functionally graded component
in other words increases the percentage of NiCr hardness value
increases because NiCr rich region has FCC structure whereas SS
rich region has BCC structure [28] uniform interface region
achieved using LENS fabricated FGM component of SS316L and
IN625, in the microstructure bcc ferrite, fcc austenite, carbide
and martensite are found [48] found that columnar texture
along h0 0 1i direction in both SS316L and IN718, it expects FCC
crystal structure when building direction aligned with compatible
grain growth for crystal structure. It is because of both material
shows coherent grain growth across interface.
To improve the properties of SS-Ni part researcher applied var-
ious strategies such as [49] researcher added carbon fibre between
SS316L and IN718, due to carbon fibre large carbides formed, the
addition of carbon fibre improves the wear resistant of the compo-
nent [10] uses LMD integrated with preheating for fabrication of
FGM part of SS316L and IN625, preheating leads to transformed
lave phases to carbide phases and achieve prominent columnar
dendrites [50] there is no diffusion layer formed when applied a
thermal milling between the deposition of each powder. No ele-
ment segregation found on SS316L, whereas Nb segregation found
on IN718. Researcher [51] performed numerical modelling and
experimental analysis for the printability and microstructure of
SS316L and IN718 component using direct energy deposition, in
a multi-material component increase number of layers leads to
heat accumulation are more prone to compositional changes
defects and distortion. While on the other hand, for initial layer
fabrication lack of fusion occurs due to heat loss through the sub-
strate. Due to difference of CTE, last layer of IN718 is prone to dis-
tortion, whereas SS316L has lack of fusion and compositional
R. Singh Tanwar and S. Jhavar
change found for the initial layers [52] varying the percentage of
one material during fabrication, there is irregular changes observed
it is due to segregation of material during solidification. As increas-
ing the percentage of SS316L, Nb and Mo precipitation found along
the length of cracks, whereas percentage of IN718 leads to lave
phases. Increase the cooling rate hinder the growth of segregation
and lave phases. When fabrication starts, cooling rate is high
because heat transferred quickly to substrate, it results less Nb seg-
regation and lave phases [41,53] there is no cracks or pores are
observed during fabrication of IN718/316L using LMD because
both materials are completely adhered to each other. Increasing
the percentage of IN718 gives deep dimple and sharp tearing edges
observed by fracture morphologies of tensile test [24] fabricated
FGM component of different variation of IN718 and SS316L, there
are defects are found it is because of high laser irradiation oxida-
tion of ceramic compound Al2O3 and TiO2 are formed [18] using
WAAM, fabricated bimetallic component of Nickel-aluminium-
bronze (NAB) with SS316L, liquification cracks are observed at
the NAB/SS interface, these are intragranular cracks and propa-
gated in the heat affected zone direction. It is occurred due to phys-
ical property (such as coefficient of thermal expansion, melting
point etc.) difference between NAB and SS alloy. Cracks can be min-
imized by optimizing the heat input [42]. Multi-material SS316L
and IN718 fabricated through selective laser melting (SLM), there
are very narrow region found at the interface it shows it has good
bonding strength, some cracks and pores are observed through
optical microscopy. Due to unmolten particles at interface, lower
thermal stresses, nucleation, and growth of micro-voids occurs at
the interface it leads to cracks at SS316L side [10] researcher
observed that more cracks are observed at the higher percentage
of SS316L, it is because Mo and Nb precipitate formed. While in
case of preheated sample no cracks are observed [8] uses liquid
dispersed metal powder bed fusion to fabricate Inconel-steel alter-
nate layers multi-metal part. Researcher concluded that by varying
the percentage of metal powder able to tailored the properties as
per requirement. Researcher [54] fabricated a component using
Laser Engineered Net Shaping (LENS), XRD analysis conforms, there
is no variation in peaks for the gradient section it shows uniform
microstructure [55] reported using EBM form a less precipitate as
compared to DED for bimetallic component [38] reported that
XRD analysis conforms the lave phases segregated with element
of Nb and Mo. [56] during production of IN718 and SS316L using
LPBF, elemental diffusion of nickel concentration reduces whereas
iron concentration increases.
3.2. Mechanical properties
Based on the literature review, various test has been performed
by the researchers such as tensile testing, wear testing, hardness
test and observe the fracture surface of SS-Ni multi-material fabri-
cated through different AM methods [39] researcher found that
mixed portion has lower hardness and tensile strength as com-
pared to the unmixed single alloy it is because of carbide and lave
phases weaken the mixed portion. Also found the optimum mixed
proportion to achieve highest strength and ductility [46]
researcher observed that tensile strength is proportional to mass
flow of powder rate whereas inversely proportional to laser power
[26] perform machinability test on SS316L and IN718 component,
at a section where IN718 content more than SS316L it shows
higher hardness and strength. It results it exhibit higher cutting
force and more heat is generated [57,58] using Laser DED fabri-
cated alternate layers of IN718 and SS316L, during the fabrication
researcher found sharp interface and gradual interface, sharp inter-
face found because of low laser power setting for IN718 deposition
it is not enough for SS316L, gradual interface found because of high
laser power and sufficient to melt both metals, the microhardness
5
Materials Today: Proceedings xxx (xxxx) xxx
value varies along the length of gradient zone [51]. Due to
microstructure coarsening, hardness variation is observed in
multi-material part with increasing the number of layers more
hardness observed at the IN718 side, it is because of higher yield
strength of material matrix and laves intermetallic phases in the
mixed region remarkable changes are observed in microhardness
it is because of the dilution of SS316L and IN718 mixed and solid-
ified. Hardness reduces due to diffusion of solid-solution reinforced
particles. For a graded sample. Ultimate tensile strength, yield
strength, and elongation is less than the single material it is
because of difference in properties of materials it leads to defects
and stress concentration. Researcher fabricated two sample
grade10 (i.e., variation of IN718 10% per layer) and grade25 (i.e.,
variation of Inconel 25%), grade25 has many deeper dimples are
found at the fracture surface it shows ductile fracture whereas
grade shows brittle fracture, it is because of pores and stress con-
centration by internal cracks.
The heat rate and feed stock rate plays an important role to fab-
ricate a defect free component, these two parameters should be
optimum, there are four possible cases such as 1) laser power
and powder feed rate both are low it leads to under-deposition,
2) in the same if both parameters are high it leads to over-
deposition, 3) if laser power is low and powder feed rate is high
it leads to lack of fusion, and 4) if laser power high and powder feed
rate low generated keyhole and porosity. Fig. 3 represents the rela-
tionship between these paramters. Pitting resistance and corrosion
resistance reduces due to depletion of Mo and Nb during EBM AM
of SS316L and IN718. LENS used to fabricate SS316L and IN718
multi-material component, from the microchemical analysis found
that there is small variation in between theoretical and experimen-
tal value it is because of SS316L not meted properly at the transi-
tion zone [59]. Cr and Ni content higher whereas Fe content lower
than the expected value [50] researcher uses hybrid additive man-
ufacturing (laser DED and thermal milling) for the fabrication of
bimetal steel and Inconel, for each metal powder deposition ther-
mal milling applied to surface quality and dimensional accuracy
achieved. The tensile properties of mixed material lower than the
both base metals, and fracture surface morphology similar to
SS316L fracture morphology with large number of strip bulges
[42] fracture surface of the mixed region of SS316L and IN718
SLM part shows dimples, flat ridges, sharp edges, and gradual
ridge, it shows it has ductile and brittle fracture [40] researcher
performed hardness and wear test for mechanical characterization,
microhardness increases as increase the percentage of IN718 due
to increase of Cr, Mo etc. content its effect on solid solution
Fig. 3. Infulence of heat rate and feed stock rate in defect formation.
R. Singh Tanwar and S. Jhavar
strengthening. The coefficient of friction and width of wear scars
increases and decreases respectively as increases the percentage
of IN718. IN718 increases brittleness due to intermetallic com-
pound and carbide particles formed, which flakes easily during
friction [60] reduced modulus observed at increased transition
from IN718 to 316L due to elastic properties of both materials
depends on closed packed nature of FCC crystal structure and iden-
tical bonding strength for both metal alloys. There is no significant
crack propagation effect observed on dissimilar material interface
under increasing DK condition. Whereas, considering lower stress
intensity factor values influences orientation and grain structure
leads crack propagation rate. It is because of IN718 shows large
columnar grain structure shows continuous growth while 316L
more equiaxed grains results local crack propagation occurs at
lower stress intensity level
4. Conclusion and future work
It is exhilarating to see additive manufacturing methods such as
LPBF, LDED, EBM and WAAM successfully fabricate multi-material
SS-Ni part.
 To optimize the parameters SS-Ni multi-material is successfully
fabricated through AM processes.
 In FGM and bimetallic component has equiaxed grains in SS420
whereas IN718 shows columnar grains with dendrite structure.
In mixed portion of SS420 and IN718 shows has carbide and
lave phases, carbide phases formed due to presence of reactive
metallic element such as Mo and Nb.
 In LDED and WAAM, tensile strength is proportional mass flow
rate of powder or wire, whereas inversely proportional to heat
source.
 Microhardness of SS-Ni multi-material part varies along the
length of gradient zone.
 Fracture surface of the mixed region of SS316L and IN718 SLM
part shows dimple, flat ridges, sharp edges, and gradual ridges
found, it shows it has ductile and brittle fracture.
The future work suggested such as corrosion and fatigue beha-
viour, machinability test perform to evaluate novel information for
the future application. AM fabrication process equipped with high
end monitoring and sensor system to obtain In-Situ information to
understand microstructure and phase evaluation. Optimization of
parameters using machine learning, artificial intelligence, numeri-
cal modelling applied on AM fabricated components of SS-Ni
multi-material gives a new age for the future applications.
Data availability
No data was used for the research described in the article.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
References
[1] C. Beyer, Strategic implications of current trends in additive manufacturing, J.
Manuf. Sci. Eng. Trans. ASME 136 (6) (2014), https://doi.org/10.1115/
1.4028599.
[2] S. Ford, ‘‘Accepted Manuscript,” 2016, doi: 10.1016/j.jclepro.2016.04.150.
[3] S. Hasanov et al., Review on additive manufacturing of multi-material parts:
progress and challenges, J. Manuf. Mater. Process. 6 (1) (2022), https://doi.org/
10.3390/jmmp6010004, MDPI.
6
Materials Today: Proceedings xxx (xxxx) xxx
[4] N.E. Putra, M.J. Mirzaali, I. Apachitei, J. Zhou, A.A. Zadpoor, Multi-material
additive manufacturing technologies for Ti-, Mg-, and Fe-based biomaterials
for bone substitution, Acta Biomaterialia 109 (2020) 1–20, https://doi.org/
10.1016/j.actbio.2020.03.037, Acta Materialia Inc.
[5] S.M. Banait, C.P. Paul, A.N. Jinoop, H. Kumar, R.S. Pawade, K.S. Bindra,
Experimental investigation on laser directed energy deposition of
functionally graded layers of Ni-Cr-B-Si and SS316L, Opt. Laser Technol. 121
(Jan. 2020), https://doi.org/10.1016/j.optlastec.2019.105787.
[6] S. Jhavar, Wire arc additive manufacturing: approaches and future prospects,
Additive Manuf. Elsevier (2021) 183–208, https://doi.org/10.1016/B978-0-12-
822056-6.00004-7.
[7] D. Herzog, V. Seyda, E. Wycisk, C. Emmelmann, Additive manufacturing of
metals, Acta Mater. 117 (Sep. 2016) 371–392, https://doi.org/10.1016/j.
actamat.2016.07.019.
[8] S.C. Bodner et al., Inconel-steel multilayers by liquid dispersed metal powder
bed fusion: microstructure, residual stress and property gradients, Addit.
Manuf. 32 (Mar. 2020), https://doi.org/10.1016/j.addma.2019.101027.
[9] J. Chen, Y. Yang, C. Song, M. Zhang, S. Wu, D. Wang, Interfacial microstructure
and mechanical properties of 316L /CuSn10 multi-material bimetallic
structure fabricated by selective laser melting, Mater. Sci. Eng. A 752 (Apr.
2019) 75–85, https://doi.org/10.1016/j.msea.2019.02.097.
[10] W. Meng, W. Zhang, W. Zhang, X. Yin, B. Cui, Fabrication of steel-Inconel
functionally graded materials by laser melting deposition integrating with
laser synchronous preheating, Opt. Laser Technol. 131 (Nov. 2020), https://doi.
org/10.1016/j.optlastec.2020.106451.
[11] U. Savitha, G.J. Reddy, V. Singh, A.A. Gokhale, M. Sundararaman, Additive laser
deposition of compositionally graded NiCrAlY-YSZ multi-materials on IN625-
NiCrAlY substrate, Mater. Charact. 164 (2020), https://doi.org/10.1016/
j.matchar.2020.110317.
[12] L. Yan, Y. Chen, F. Liou, Additive manufacturing of functionally graded metallic
materials using laser metal deposition, Additive Manuf. 31 (2020), https://doi.
org/10.1016/j.addma.2019.100901.
[13] J. Sun, H. Yu, D. Zeng, P. Shen, Wire–powder–arc additive manufacturing: a
viable strategy to fabricate carbide ceramic/aluminum alloy multi-material
structures, Addit. Manuf. 51 (2022), https://doi.org/10.1016/j.
addma.2022.102637.
[14] A. Bandyopadhyay, Y. Zhang, B. Onuike, Additive manufacturing of bimetallic
structures, in: Virtual and Physical Prototyping, Taylor and Francis Ltd., 2022,
pp. 256–294.
[15] C. Zhang et al., Additive manufacturing of functionally graded materials: a
review, Mater. Sci. Eng. A 764 (2019), https://doi.org/10.1016/j.
msea.2019.138209.
[16] A.G. Demir, B. Previtali, Multi-material selective laser melting of Fe/Al-12Si
components, Manuf. Lett. 11 (2017) 8–11, https://doi.org/10.1016/j.
mfglet.2017.01.002.
[17] S.L. Sing, L.P. Lam, D.Q. Zhang, Z.H. Liu, C.K. Chua, Interfacial characterization of
SLM parts in multi-material processing: Intermetallic phase formation
between AlSi10Mg and C18400 copper alloy, Mater. Charact. 107 (Jul. 2015)
220–227, https://doi.org/10.1016/j.matchar.2015.07.007.
[18] C. Dharmendra, S. Shakerin, G.D.J. Ram, M. Mohammadi, Wire-arc additive
manufacturing of nickel aluminum bronze/stainless steel hybrid parts –
Interfacial characterization, prospects, and problems, Materialia 13 (July)
(2020), https://doi.org/10.1016/j.mtla.2020.100834.
[19] B. Onuike, A. Bandyopadhyay, Additive manufacturing of Inconel 718 –
Ti6Al4V bimetallic structures, Addit. Manuf. 22 (2018) 844–851, https://doi.
org/10.1016/j.addma.2018.06.025.
[20] B. Onuike, A. Bandyopadhyay, Functional bimetallic joints of Ti6Al4V to SS410,
Addit. Manuf. 31 (2020), https://doi.org/10.1016/j.addma.2019.100931.
[21] C. Wei et al., Fabrication of diamond/W–Cu functionally graded material by
microwave sintering, Nucl. Eng. Technol. 54 (3) (2022) 975–983, https://doi.
org/10.1016/j.net.2021.08.035.
[22] M.K. Sinha, R. Madarkar, S. Ghosh, P.V. Rao, Application of eco-friendly
nanofluids during grinding of Inconel 718 through small quantity lubrication,
J. Clean. Prod. 141 (2017) 1359–1375, https://doi.org/10.1016/j.
jclepro.2016.09.212.
[23] P. Boillot, J. Peultier, Use of stainless steels in the industry: Recent and future
developments, Procedia Eng. 83 (2014) 309–321, https://doi.org/10.1016/j.
proeng.2014.09.015.
[24] S.H. Kim et al., Selective compositional range exclusion via directed energy
deposition to produce a defect-free Inconel 718/SS 316L functionally graded
material, Addit. Manuf. 47 (2021), https://doi.org/10.1016/j.
addma.2021.102288.
[25] M.R.U. Ahsan et al., Microstructures and mechanical behavior of the bimetallic
additively-manufactured structure (BAMS) of austenitic stainless steel and
Inconel 625, J. Mater. Sci. Technol. 74 (2021) 176–188, https://doi.org/
10.1016/j.jmst.2020.10.001.
[26] B. Li, R. Zhang, A. Malik, W. Li, Machinability of partition milling stainless steel/
Inconel functionally gradient material printed with directed energy
deposition, Int. J. Adv. Manuf. Technol. 122 (7–8) (2022) 3009–3022, https://
doi.org/10.1007/s00170-022-10111-8.
[27] ‘‘Designation: F2792
12a”, doi: 10.1520/F2792-12A.
[28] I. Meera Mirzana, G. Krishana Mohana Rao, S. ur Raheman, M. Zaki Ahmed,
Fabrication and Micro-structural study of Functionally Graded Material Disc of
SS316/IN625, Mater. Today Proc. 3 (10) (2016) 4236–4241, https://doi.org/
10.1016/j.matpr.2016.11.103.
R. Singh Tanwar and S. Jhavar
[29] M.R.U. Ahsan, A.N.M. Tanvir, T. Ross, A. Elsawy, M.S. Oh, D.B. Kim, Fabrication
of bimetallic additively manufactured structure (BAMS) of low carbon steel
and 316L austenitic stainless steel with wire + arc additive manufacturing,
Rapid Prototyp. J. 26 (3) (2020) 519–530, https://doi.org/10.1108/RPJ-09-
2018-0235.
[30] B. Onuike, A. Bandyopadhyay, Additive manufacturing in repair: Influence of
processing parameters on properties of Inconel 718, Mater. Lett. 252 (2019)
256–259, https://doi.org/10.1016/j.matlet.2019.05.114.
[31] D. Svetlizky et al., Directed energy deposition (DED) additive manufacturing:
physical characteristics, defects, challenges and applications, Mater. Today 49
(2021) 271–295, https://doi.org/10.1016/j.mattod.2021.03.020.
[32] L.D. Bobbio, B. Bocklund, Z.-K. Liu, A.M. Beese, Tensile behavior of stainless
steel 304L to Ni-20Cr functionally graded material: experimental
characterization and computational simulations, Materialia 18 (2021),
https://doi.org/10.1016/j.mtla.2021.101151.
[33] P.F. Jiang et al., Multi-wire arc additive manufacturing of Ti basic
heterogeneous alloy: effect of deposition current on the microstructure,
mechanical property and corrosion-resistance, J. Alloys Compd. 920 (2022),
https://doi.org/10.1016/j.jallcom.2022.166056.
[34] D. Klobčar, S. Baloš, M. Bašić, A. Djurić, M. Lindič, A. Ščetinec, WAAM and other
unconventional metal additive manufacturing technologies, Adv. Technol.
Mater. 45 (2) (2020) 1–9, https://doi.org/10.24867/atm-2020-2-001.
[35] T. Hauser et al., Multi-Material Wire Arc Additive Manufacturing of low and
high alloyed aluminium alloys with in-situ material analysis, J. Manuf. Process.
69 (2021) 378–390, https://doi.org/10.1016/j.jmapro.2021.08.005.
[36] T.A. Rodrigues et al., Wire and arc additive manufacturing of 316L stainless
steel/Inconel 625 functionally graded material: development and
characterization, J. Mater. Res. Technol. 21 (2022) 237–251, https://doi.org/
10.1016/j.jmrt.2022.08.169.
[37] U. Gürol, B. Turgut, N. Güleçyüz, S. Dilibal, M. Koçak, Development of multi-
material components via robotic wire arc additive manufacturing, Int. J. 3D
Print. Technol. Digit. Ind. (2021), https://doi.org/10.46519/ij3dptdi.1033374.
[38] Y. Su, B. Chen, C. Tan, X. Song, J. Feng, Influence of composition gradient
variation on the microstructure and mechanical properties of 316 L/
Inconel718 functionally graded material fabricated by laser additive
manufacturing, J. Mater. Process. Technol. 283 (2020), https://doi.org/
10.1016/j.jmatprotec.2020.116702.
[39] B. Aydogan, A. O’Neil, H. Sahasrabudhe, Microstructural and mechanical
characterization of stainless steel 420 and Inconel 718 multi-material
structures fabricated using laser directed energy deposition, J. Manuf.
Process. 68 (2021) 1224–1235, https://doi.org/10.1016/j.jmapro.2021.06.031.
[40] X. Liang, D. Wu, Q. Li, L. Jiang, Laser rapid manufacturing of stainless steel
316L/Inconel718 functionally graded materials: Microstructure evolution and
mechanical properties, Int. J. Opt. 2010 (2010) 1–6, https://doi.org/10.1155/
2010/802385.
[41] W. Li, X. Chen, L. Yan, J. Zhang, X. Zhang, F. Liou, Additive manufacturing of a
new Fe-Cr-Ni alloy with gradually changing compositions with elemental
powder mixes and thermodynamic calculation, Int. J. Adv. Manuf. Technol. 95
(1–4) (2018) 1013–1023, https://doi.org/10.1007/s00170-017-1302-1.
[42] X. Mei, X. Wang, Y. Peng, H. Gu, G. Zhong, S. Yang, Interfacial characterization
and mechanical properties of 316L stainless steel/inconel 718 manufactured
by selective laser melting, Mater. Sci. Eng. A 758 (2019) 185–191, https://doi.
org/10.1016/j.msea.2019.05.011.
[43] Y. Xia, M. Peng, H. Teng, Y. Chen, X. Zhang, Multi-properties optimization of
welding parameters of wire arc additive manufacture in dissimilar joint of
iron-based alloy and nickel-based superalloy using grey-based Taguchi
method, Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci. 235 (23) (2021)
6984–6995, https://doi.org/10.1177/09544062211008928.
[44] S. Mohan Kumar et al., Microstructural features and mechanical integrity of
wire arc additive manufactured SS321/Inconel 625 functionally gradient
material, J. Mater. Eng. Perform. 30 (8) (2021) 5692–5703, https://doi.org/
10.1007/s11665-021-05617-3.
Materials Today: Proceedings xxx (xxxx) xxx
[45] J. Rodriguez, K. Hoefer, A. Haelsig, P. Mayr, ‘‘Functionally graded SS 316l to ni-
based structures produced by 3D plasma metal deposition, Metals (Basel) 9 (6)
(2019), https://doi.org/10.3390/met9060620.
[46] K. Shah, I. ul Haq, A. Khan, S.A. Shah, M. Khan, A.J. Pinkerton, Parametric study
of development of Inconel-steel functionally graded materials by laser direct
metal deposition, Mater. Des. 54 (2014) 531–538, https://doi.org/10.1016/
j.matdes.2013.08.079.
[47] N. Chen et al., Microstructural characteristics and crack formation in additively
manufactured bimetal material of 316L stainless steel and Inconel 625, Addit.
Manuf. 32 (Mar. 2020), https://doi.org/10.1016/j.addma.2020.101037.
[48] M.S. Duval-Chaneac et al., Fatigue crack growth in IN718/316L multi-materials
layered structures fabricated by laser powder bed fusion, Int. J. Fatigue 152
(April) (2021), https://doi.org/10.1016/j.ijfatigue.2021.106454.
[49] A.I. Gorunov, Investigation microstructure of carbon fibers reinforced
composite on Fe and Ni-based obtained by laser metal deposition, Surf.
Coatings Technol. 364 (2019) 279–288, https://doi.org/10.1016/
j.surfcoat.2019.03.006.
[50] P. Li, Y. Gong, Y. Xu, Y. Qi, Y. Sun, H. Zhang, Inconel-steel functionally bimetal
materials by hybrid directed energy deposition and thermal milling:
Microstructure and mechanical properties, Arch. Civ. Mech. Eng. 19 (3)
(2019) 820–831, https://doi.org/10.1016/j.acme.2019.03.002.
[51] R. Ghanavati, H. Naffakh-Moosavy, M. Moradi, M. Eshraghi, Printability and
microstructure of directed energy deposited SS316l-IN718 multi-material:
numerical modeling and experimental analysis, Sci. Rep. 12 (1) (2022) 16600,
https://doi.org/10.1038/s41598-022-21077-8.
[52] S.W. Yang, J. Yoon, H. Lee, D.S. Shim, Defect of functionally graded material of
inconel 718 and STS 316L fabricated by directed energy deposition and its
effect on mechanical properties, J. Mater. Res. Technol. 17 (2022) 478–497,
https://doi.org/10.1016/j.jmrt.2022.01.029.
[53] Y. Su, B. Chen, C. Tan, X. Song, J. Feng, Influence of composition gradient
variation on the microstructure and mechanical properties of 316 L/
Inconel718 functionally graded material fabricated by laser additive
manufacturing, J. Mater. Process. Technol. 283 (2020), https://doi.org/
10.1016/j.jmatprotec.2020.116702.
[54] X. Tong, C. Lu, Z. Huang, C. Zhang, F. Chen, Microstructures and mechanical
properties of crack-free 316L stainless steel and Inconel 625 joint by using
Laser Engineered Net Shaping, Opt. Laser Technol. 155 (2022), https://doi.org/
10.1016/j.optlastec.2022.108357.
[55] A. Hinojos et al., Joining of Inconel 718 and 316 Stainless Steel using electron
beam melting additive manufacturing technology, Mater. Des. 94 (2016) 17–
27, https://doi.org/10.1016/j.matdes.2016.01.041.
[56] W.W. Wits, E. Amsterdam, Graded structures by multi-material mixing in laser
powder bed fusion, CIRP Ann. 70 (1) (2021) 159–162, https://doi.org/10.1016/
j.cirp.2021.03.005.
[57] B.E. Carroll et al., Functionally graded material of 304L stainless steel and
inconel 625 fabricated by directed energy deposition: Characterization and
thermodynamic modeling, Acta Mater. 108 (2016) 46–54, https://doi.org/
10.1016/j.actamat.2016.02.019.
[58] D. Melzer, J. Džugan, M. Koukolíková, S. Rzepa, J. Vavřík, Structural integrity
and mechanical properties of the functionally graded material based on 316L/
IN718 processed by DED technology, Mater. Sci. Eng. A 811 (2021), https://doi.
org/10.1016/j.msea.2021.141038.
[59] U. Savitha, G. Jagan Reddy, A. Venkataramana, A. Sambasiva Rao, A.A. Gokhale,
M. Sundararaman, Chemical analysis, structure and mechanical properties of
discrete and compositionally graded SS316–IN625 dual materials, Mater. Sci.
Eng. A 647 (2015) 344–352, https://doi.org/10.1016/j.msea.2015.09.001.
[60] M.S. Duval-Chaneac et al., Fatigue crack growth in IN718/316L multi-materials
layered structures fabricated by laser powder bed fusion, Int. J. Fatigue 152
(2021), https://doi.org/10.1016/j.ijfatigue.2021.106454.