EVALUATION OF THE PROCESS PARAMETER AND PERFORMANCE OF L-DED SS316L-IN718 BIMETALLIC STRUCTURES

Year 2025, Volume: 9 Issue: 2, 263 - 271, 30.08.2025

Mustafa Kaş , Oğuzhan Yılmaz

https://doi.org/10.46519/ij3dptdi.1700837

Abstract

Laser Direct Energy Deposition (L-DED) is a promising additive manufacturing technique with potential application in joining two dissimilar materials to fabricate bi-metallic components. The quality and functionality of the bonding interfaces are of great significance and rely heavily on the process parameters. In this work, we first deposited IN718 on a wrought SS316L substrate to create a bimetallic interface. Different energy density values, ranging from 71.43 to 127.7 J/mm, were used through various combinations of laser power and scanning speed for deposition. The bimetallic interface quality in terms of interface geometry, morphology, and dilution values was investigated for every energy density. Geometric analyses and dilution measurements revealed that the optimum bimetallic fabrication was achieved with an energy density of 90–100 J/mm. To deposit bimetallic SS316L-IN718 blocks for mechanical testing, the laser power and scan speed were set to 1400 W and 14 mm/s, respectively. Line EDS measurements revealed a transition zone across the bimetallic interface within a 4 mm distance, avoiding abrupt chemical discontinuities. Micro-hardness testing using Vickers revealed a smooth hardness transition between the SS316L (~210 HV) and IN718 (~300 HV) sides without any defect formation, suggesting successful joining. The bimetallic structure exhibited yield strength of 268.88 ± 20 MPa, tensile strength of 462 ± 12 MPa, and elongation of 19.6 ± 0.8%, in good agreement with SS316L. The fracture occurred on the SS316L side with noticeable necking and ductile behavior, demonstrating good interfacial bonding. These findings demonstrate the potential of L-DED in the fabrication of bimetallic structures for structural applications.

Keywords

L-DED , Bi-metal , SS316L , IN718

Supporting Institution

Gazi Üniversitesi Bap Birimi

Project Number

FOA-2023-8507

Thanks

Yazarlar, FOA-2023-8507 proje kodlu Öncelikli Alanlar Araştırma Projesi kapsamında sağladıkları finansal destekten ötürü Gazi Üniversitesi BAP Birimi'ne, teşekkür ederler.

References

• 1. Kar, J., Roy, S.K., Roy, G.G., “Effect of beam oscillation on electron beam welding of copper with AISI-304 stainless steel”, Journal of Material Processing Technology, Vol. 223, Pages 174-185, 2016.
• 2. Alontseva, D., Yavuz, H.İ., Azamatov, B., Khoshnaw, F., Safarova, Y., Dogadkin, D., Avcu, E., Yamanoglu, R., “Improving corrosion and wear resistance of 316L stainless steel via in situ pure Ti and Ti6Al4V coatings: tribocorrosion and electrochemical analysis”, Materials, Vol. 18, Issue 3, Pages 553, 2025.
• 3. Sherpa, B.B., Rani, R., “Advancements in explosive welding process for bimetallic material joining: A review”, Journal of Alloys and Metallurgical Systems, Vol. 6, 2024.
• 4. Wu H., Xie, X., Liu, S., Xie, S., Huang, R., Verdy, C., Liu, M., Liao, H., Deng, S., Xie, Y., “Bonding behavior of bi-metal-deposits produced by hybrid cold spray additive manufacturing”, Journal of Materials Processing Technology, Vol. 299, 2022.
• 5. Singh, S., Berndt, C.C., Singh Raman, R.K., Singh, H., Ang, A.S.M., “Applications and developments of thermal spray coatings for the iron and steel industry”, Materials, Vol. 16, Issue 2, Page 516, 2023.
• 6. Chauhan, P. K., Khan, S., “Microstructural examination of aluminum-copper functionally graded material developed by powder metallurgy route”, Materials Today: Proceedings, Vol. 25, Issue 4, 2020.
• 7. Yilmaz, O., Çelik, H., “Electrical and thermal properties of the interface at diffusion-bonded and soldered 304 stainless steel and copper bimetal”, Journal of Materials Processing Technology, Vol. 141, Issue 1, Pages 67-76, 2003,
• 8. Wang, D., Liu, L., Deng, G., Deng, C., Bai, Y., Yang, Y., Han, C., “Recent progress on additive manufacturing of multi-material structures with laser powder bed fusion”, Virtual and Physical Prototyping, Vol. 17, Issue 2, Pages 329–365, 2022.
• 9. Bandyopadhyay, A., Zhang, Y., Onuike, B., “Additive manufacturing of bimetallic structures”, Virtual and Physical Prototyping, Vol. 17, Issue 2, Pages 256–294, 2022.
• 10. Dass, A., Moridi, A., “State of the art in directed energy deposition: From additive manufacturing to materials design”, Coatings, Vol. 9, Pages 415, 2019.
• 11. Gürol U., Dilibal S., Turgut B., Baykal H., Kümek H., Koçak M., “Manufacturing and characterization of WAAM-based bimetallic cutting equipment”, International Journal of 3D Printing Technologies and Digital Industry, Vol. 6, Issue 3, Pages 548-555, 2022.
• 12. Tan, Z. E., Pang, J. H. L., Kaminski, J., Pepin, H., “Characterization of porosity, density, and microstructure of directed energy deposited stainless steel AISI 316L”, Additive Manufacturing, Vol. 25, Pages 286-296, 2019.
• 13. Benarji, K., Kumar, Y., Paul, C., Jinoop, A., Bindra, K., “Parametric investigation and characterization on SS316 built by laser-assisted directed energy deposition”, Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications, Vol. 234, Issue 3, Pages 452-466, 2019.
• 14. Mahmud, A., Ayers, N., Huynh, T., Sohn, Y., “Additive manufacturing of SS316l/IN718 bimetallic structure via laser powder bed fusion”, Materials, Vol. 16, Issue 19, Page 6527, 2023.
• 15. Singh, S. P., Aggarwal, A., Upadhyay, R. K., Kumar, A., “Processing of IN718-SS316L bimetallic-structure using laser powder bed fusion technique”, Materials and Manufacturing Processes, Vol. 36, Issue 9, Pages 1028-1039, 2021.
• 16. Nouri, A., Wen, C., “Stainless steels in orthopedics”, In Structural Biomaterials, Pages 67-101, 2021.
• 17. Zhou, C., Wang, J., Hu, S., Tao, H., Fang, B., Long, L., Zhang, L., “Enhanced corrosion resistance of additively manufactured 316L stainless steel after heat treatment”, Journal of the Electrochemical Society, Vol. 167, Issue 14, Page 141504, 2020.
• 18. Vikram, R., Kirchner, A., Klöden, B., Suwas, S., “Optimized heat treatment for electron beam powder bed fusion processed IN718: correlating microstructure, texture, and mechanical properties”, Advanced Engineering Materials, Vol. 27, Issue 9, 2025.
• 19. Xu, J., Wu, Z., Niu, J., Song, Y., Liang, C., Yang, K., Chen, Y., Liu, Y., “Effect of laser energy density on the microstructure and microhardness of inconel 718 alloy fabricated by selective laser melting”, Crystals, Vol.12, Issue 9, Pages 2022.
• 20. Chen, Z., Sun, W., Huang, Y., Zhou, H., Yang, K., Lu, J., “The effect of laser energy density on microstructural evolution and mechanical properties of laser clad 316L stainless steel for repair”, Surface and Coatings Technology, Vol. 448, 2022.
• 21. Saboori, A., Aversa, A., Marchese, G., Biamino, S., Lombardi, M., Fino, P., “Application of directed energy deposition-based additive manufacturing in repair”, Applied Sciences Vol. 9, Issue 16, Page 3316, 2019.
• 22. Kas, M., Muslim, T., Yilmaz, O. Karagoz, T., Turedi, E., Gumus. S., Bayram, A., “Directed energy deposition of PH 13–8 Mo stainless steel: microstructure and mechanical property analysis”, International Journal Advanced Manufacturing Technology, Vol. 132, Pages 701–715, 2024. 23. Sampson, R., Lancaster, R., Sutcliffe, M., Carswell, D., Hauser, C., Barras, J., “The influence of key process parameters on melt pool geometry in direct energy deposition additive manufacturing systems”, Optics & Laser Technology, Vol. 134, 2021.
• 24. Grandhi, M., Nagaraj, A., Khosravi, H., Liu, Z., Min, S., “Mechanical and microstructural profiling of additively manufactured cobalt–nickel functional gradient structure”, Manufacturing Letters, Vol. 41, 2024.
• 25. Ji, C., Li, K., Zhan, J., Bai, S., Jiang, B., Murr, L. E., “The effects and utility of homogenization and thermodynamic modeling on microstructure and mechanical properties of SS316/IN718 functionally graded materials fabricated by laser-based directed energy deposition”, Journal of Materials Processing Technology, Vol. 319, 2023.
• 26. Lu, J., Li, W., “Improvement of tensile properties of laser directed energy deposited IN718/316L functionally graded material via different heat treatments”, Materials Science and Engineering: A, Vol. 866, 2023.