MULTI-MATERIAL FABRICATION OF STAINLESS STEEL TO NICKEL ALLOY PARTS USING DIRECT LASER METAL DEPOSITION: A REVIEW

Abstract

Direct Laser Metal Deposition (DLMD) employs additive manufacturing (AM) techniques for multi-material components, including stainless steel to nickel-based superalloys. It is applicable in aerospace, energy, and hightemperature applications because to its exceptional mechanical strength, corrosion resistance, and thermal stability. The article reviews the DLMD manufacturing method for multi-material parts, equipment schematics, and microstructural organization of stainless steel 316L in relation to Inconel 625 and Inconel 718, emphasizing hardness gradients, tensile strength, residual stress buildup, and thermal distortion. Despite its advantages, multi-material DLMD faces challenges such solidification cracking, porosity, phase segregation, and interfacial stress concentration, which may undermine structural integrity. Consequently, many strategies are suggested to improve quality and decrease defects, such as optimizing process parameters, applying real-time monitoring, and utilizing AI and Machine Learning in the design and manufacturing of multi-material components.