Recent Advancements in Hybrid Additive Manufacturing of Similar and Dissimilar Metals via Laser Powder Bed Fusion

Additive Manufacturing (AM) is a transformative technology that facilitates the production of intricate geometries with high precision, customization, and speed. While conventional AM processes for metallic components have traditionally involved single materials, there is a growing demand for hybrid components made from two or more metals. This paper comprehensively reviews the state-of-the-art in multi-material AM for metallic parts using Laser Powder Bed Fusion (LPBF). It delves into an in-depth analysis of the interface characteristics and properties of bimetallic LPBF parts, offering valuable insights into the complex process-structure-property relations involved in joining similar and dissimilar metals. Research on similar hybrid metals has emphasized the significant potential of this method for efficiently producing robust joints across various classes of ferrous and non-ferrous metals. Moreover, the article addresses the inherent challenges in hybrid 3D printing of dissimilar metals, including substantial differences in physical and chemical properties, the formation of detrimental intermetallic compounds, and element segregation. In response to these obstacles, the study thoroughly explores various strategies proposed in the literature, such as adjusting process parameters, integrating an interlayer of a third material, and utilizing machine learning algorithms. Additionally, it outlines the applications and future directions in AM of hybrid LPBF structures, providing a complete roadmap for potential research in this rapidly evolving field.