Skip to main content

Advertisement

SpringerLink
Log in

Additive manufacturing of metal-based functionally graded materials: overview, recent advancements and challenges

  • Review
  • Published:
Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

Additive Manufacturing (AM) techniques gained significant research interest in the past two decades. AM techniques are the best alternative to traditional manufacturing processes for fabricating highly complex parts with reduced wastage. Functionally graded materials (FGMs) are heterogeneous structures with varying composition, microstructure, and site-specific properties, which is beneficial in a wide variety of applications. Manufacturing constraints in FGM by conventional manufacturing methods limit the applications. Significant advancements in AM methods form the bedrock to manufacture complex FGM structures. Applications of FGM drastically increased due to the feasibility of AM processes. The number of research publications in FGM depicts the interest in the research trend. AM was widely used to fabricate a variety of FGM’s, but certain defects developed in the FGM components due to the significant variance of thermal properties, crystallographic structures, and modulus of elasticity require focused and systematic investigation. The AM process progresses drastically to control the defects by hybrid process, using artificial intelligence (AI) controlled design and process. In the present review, various studies focused on the fabrication of FGM with stainless steels, magnesium, titanium, copper, and nickel-based superalloys have been discussed. This article reveals the important knowledge required for fabricating quality metal-based FGM structures using AM technology and its benefits in identifying future trends and challenges. Ultimately, the outlook is summarized to give direction for future research works.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30

Similar content being viewed by others

References

  1. Yin S, Yan X, Chen C, Jenkins R, Liu M, Lupoi R (2018) Hybrid additive manufacturing of Al-Ti6Al4V functionally graded materials with selective laser melting and cold spraying. J Mater Process Technol 255:650–655

    Google Scholar 

  2. Ahsan MRU, Tanvir ANM, Ross T, Elsawy A, Oh MS, Kim DB (2018) 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):519–530

    Google Scholar 

  3. Wang C, Shang C, Liu Z, Xu G, Liu X (2020) Laser additive manufacturing of bimetallic structure from TC4 to IN718 via Ta/Cu multi-interlayer. Mater Res Express 7(12):126506

    Google Scholar 

  4. Shen C, Liss KD, Reid M, Pan Z, Hua X, Li F, Mou G, Huang Y, Dong B, Luo D, Li H (2021) Effect of the post-production heat treatment on phase evolution in the Fe3Ni–FeNi functionally graded material: an in-situ neutron diffraction study. Intermetallics 129:107032

    Google Scholar 

  5. Shakerin S, Hadadzadeh A, Amirkhiz BS, Shamsdini S, Li J, Mohammadi M (2019) Additive manufacturing of maraging steel-H13 bimetals using laser powder bed fusion technique. Addit Manufact 29:100797

    Google Scholar 

  6. Shi JM, Ma N, Zhang LX, Feng JC (2018) Residual stress and fracture strength of brazed joint of ceramic and titanium alloy with the aid of laser deposited functionally graded material layers. J Manuf Process 34(2018):495–502

    Google Scholar 

  7. Wu BD, Liu X, Li JF, Zhou YZ, Yang XS, Huang XF, Le GM (2021) Tungsten-chromium coatings on reduced activation ferritic/martensitic steels prepared by laser melting deposition process. J Nucl Mater 543:152573

    Google Scholar 

  8. Ma R, Liu Z, Wang W, Xu G, Wang W (2020) Microstructures and mechanical properties of Ti6Al4V-Ti48Al2Cr2Nb alloys fabricated by laser melting deposition of powder mixtures. Mater Charact 164:110321

    Google Scholar 

  9. Liu Y, Liu W, Ma Y, Liang C, Liu C, Zhang C, Cai Q (2018) Microstructure and wear resistance of compositionally graded TiAl intermetallic coating on Ti6Al4V alloy fabricated by laser powder deposition. Surf Coat Technol 353:32–40

    Google Scholar 

  10. Li W, Karnati S, Kriewall C et al (2017) Fabrication and characterization of a functionally graded material from Ti-6Al-4V to SS316 by laser metal deposition. Addit Manuf 14:95–104

    Google Scholar 

  11. Khodabakhshi F, Farshidianfar MH, Bakhshivash S, Gerlich AP, Khajepour A (2019) Dissimilar metals deposition by directed energy based on powder-fed laser additive manufacturing. J Manuf Process 43:83–97

    Google Scholar 

  12. Ahsan MR, Fan X, Seo GJ, Ji C, Noakes M, Nycz A, Liaw PK, Kim DB (2021) Microstructures and mechanical behavior of the bimetallic additively-manufactured structure (BAMS) of austenitic stainless steel and Inconel 625. J Mater Sci Technol 74:176–188

    Google Scholar 

  13. Durakovic B (2018) Design for additive manufacturing: Benefits, trends and challenges. Periodic Eng Nat Sci 6(2):179–191

    Google Scholar 

  14. Scopus data base search: https://www.scopus.com/results/results.uri?sort=plffandsrc=sandst1=functionally+graded+materialsandsid=c057e3b15f7e669cfb3d7e98ee5fb09dandsot=bandsdt=bandsl=44ands=TITLE-ABS-KEY%28functionally+graded+materials%29andorigin=searchbasicandeditSaveSearch=andyearFrom=Before+1960andyearTo=Present accessed on 12.05.2022.

  15. Malakooti MH, Zhou Z, Sodano HA (2018) Enhanced energy harvesting through nanowire based functionally graded interfaces. Nano Energy 52:171–182

    Google Scholar 

  16. Janaki P, Karthick N, Kumar GVN (2021) Design and analysis of FGM post type spacer in a three phase common enclosure gas insulated busduct under delamination. Electric Power Syst Res 190:106834

    Google Scholar 

  17. Mahamood RM, Akinlabi ET (2017) Types of functionally graded materials and their areas of application. Functionally Graded Materials. Springer, Berlin, pp 9–21

    Google Scholar 

  18. Schaper M, Haferkamp H, Niemeyer M, Pelz C, Viets R (1999) Thermal investigation of compound cast steel tools. Thermosense XXI 3700:164–170

    Google Scholar 

  19. El-Galy IM, Saleh BI, Ahmed MH (2019) Functionally graded materials classifications and development trends from industrial point of view. SN Appl Sci 1(11):1378

    Google Scholar 

  20. Akshaya SL, Prakash A, Bharati Raj J (2020) Applications of functionally graded materials in structural engineering—a review. In: national conference on structural engineering and construction management, pp 553–566

  21. Danesh M, Ghadami A (2019) Sound transmission loss of double-wall piezoelectric plate made of functionally graded materials via third-order shear deformation theory. Compos Struct 219:17–30

    Google Scholar 

  22. Sola A, Bellucci D, Cannillo V (2016) Functionally graded materials for orthopedic applications – an update on design and manufacturing. Biotechnol Adv 34(5):504–531

    Google Scholar 

  23. Miyamoto Y (1996) The applications of functionally graded materials in japan. Mater Technol 11(6):230–236

    Google Scholar 

  24. Yadav A, Badoniya P, Srivastava M, Jain PK (2021) Rathee S (2021) Functionally graded materials: applications and future challenges. Functionally Graded Materials (FGMs). CRC Press, Boca Raton, pp 217–230

    Google Scholar 

  25. Udupa G, Rao SS, Gangadharan KV (2014) Functionally graded composite materials: an overview, Procedia. Mater Sci 5:1291–1299

    Google Scholar 

  26. Besisa DHA, Ewais EMM (2016) Advances in functionally graded ceramics–processing, sintering properties and applications. Adv Funct Graded Mater Struct 1:32

    Google Scholar 

  27. Wei C, Sun Z, Chen Q, Liu Z, Li L (2019) Additive manufacturing of horizontal and 3D functionally graded 316L/Cu10Sn components via multiple material selective laser melting. J Manufact Sci Eng 141(8):081014

    Google Scholar 

  28. Sridharan N, Gussev M, Babu S (2021) Tailoring plasticity mechanisms in compositionally graded hierarchical steels fabricated using additive manufacturing. Sci Rep 11(1):1–9

    Google Scholar 

  29. Li N, Huang S, Zhang G, Qin R, Liu W, Xiong H, Shi G, Blackburn J (2019) Progress in additive manufacturing on new materials: a review. J Mater Sci Technol 35(2):242–269

    Google Scholar 

  30. Frazier WE (2014) Metal additive manufacturing: a review. J Mater Eng Perform 23(6):1917–1928

    Google Scholar 

  31. Faludi J, Bayley C, Bhogal S, Iribarne M (2015) Comparing environmental impacts of additive manufacturing vs traditional machining via life-cycle assessment. Rapid Prototyp J 21(1):14–33

    Google Scholar 

  32. Monzón MD, Ortega Z, Martínez A, Ortega F (2015) Standardization in additive manufacturing: activities carried out by international organizations and projects. Int J Adv Manufact Technol 76:1111–1121

    Google Scholar 

  33. ISO/ASTM Internacional, (2021) Additive manufacturing - General principles terminology (ASTM52900). Rapid Manufacturing Association, pp 10–12

  34. Pereira T, Kennedy JV, Potgieter J (2019) A comparison of traditional manufacturing vs additive manufacturing, the best method for the job. Proc Manufact 30:11–18

    Google Scholar 

  35. Singh DD, Mahender T, Raji A (2021) Powder bed fusion process : a brief review. Mater Today Procee 46:350–355

    Google Scholar 

  36. Zhang X, Liou F (2021) Introduction to additive manufacturing. additive manufacturing. Elsevier, Amsterdam, pp 1–31

    Google Scholar 

  37. Pagac M, Hajnys J, Ma QP, Jancar L, Jansa J, Stefek P, Mesicek JA (2021) Review of vat photopolymerization technology. Mater Polym 13(13):598

    Google Scholar 

  38. Gibson I, Rosen D, Stucker B, Khorasani M (2021) Material jetting. In: Additive Manufacturing Technologies, Springer, pp 203–235

  39. Tang ZJ, Liu WW, Wang YW, Saleheen KM, Liu ZC, Peng ST, Zhang Z, Zhang HC (2020) A review on in situ monitoring technology for directed energy deposition of metals. Int J Adv Manufact Technol 108(11–12):3437–3463

    Google Scholar 

  40. Dass A, Moridi A (2019) State of the art in directed energy deposition: From additive manufacturing to materials design. Coatings 9(7):418

    Google Scholar 

  41. Hang ZY, Jones ME, Brady GW, Hang RJ, Griffiths D, Garcia HA, Rauch C.D. Cox, Hardwick N (2018) Non-beam-based metal additive manufacturing enabled by additive friction stir deposition. Scripta Mater 153:122–130

    Google Scholar 

  42. Dilip JJS, Ram GDJ, Stucker BE (2012) Additive manufacturing with friction welding and friction deposition processes. Int J Rapid Manufact 3(1):56–69

    Google Scholar 

  43. Sastri VR (2021) Plastics in medical devices: properties, requirements, and applications. William Andrew, Norwich

    Google Scholar 

  44. Afazov S, Roberts A, Wright L, Jadhav P, Holloway A, Basoalto H, Milne K, Brierley N (2022) Metal powder bed fusion process chains: an overview of modelling techniques. Prog Addit Manufact 7(2):289–314

    Google Scholar 

  45. Monteiro H, Carmona-Aparicio IG, Lei M (2022) Despeisse, Energy and material efficiency strategies enabled by metal additive manufacturing – a review for the aeronautic and aerospace sectors. Energy Rep 8:298–305

    Google Scholar 

  46. Ekoi EJ, Degli-Alessandrini G, Mughal MZ, Vijayaraghavan RK, Obeidi MA, Groarke R, Kraev I, Krishnamurthy S, Brabazon D (2022) Investigation of the microstructure and phase evolution across multi-material Ni50.83Ti49.17-AISI 316L alloy interface fabricated using laser powder bed fusion (L-PBF). Mater Design 221:110947

    Google Scholar 

  47. Patterson T, Hochanadel J, Sutton S, Panton B, Lippold J (2021) A review of high energy density beam processes for welding and additive manufacturing applications. Weld World 65(7):1235–1306

    Google Scholar 

  48. Brennan MC, Keist JS, Palmer TA (2021) Defects in metal additive manufacturing processes. J Mater Eng Perform 30(7):4808–4818

    Google Scholar 

  49. Mostafaei A, Zhao C, He Y, Ghiaasiaan SR, Shi B, Shao S, Shamsaei N, Wu Z, Kouraytem N, Sun T, Pauza J (2022) Defects and anomalies in powder bed fusion metal additive manufacturing. Curr Opin Solid State Mater Sci 26(2):100974

    Google Scholar 

  50. Wei C, Li L (2021) Recent progress and scientific challenges in multi-material additive manufacturing via laser-based powder bed fusion. Virtual Phys Prototyp 16(3):347–371

    Google Scholar 

  51. Beal VE, Erasenthiran P, Ahrens CH, Dickens P (2007) Evaluating the use of functionally graded materials inserts produced by selective laser melting on the injection moulding of plastics parts. Proc Inst Mech Eng Part B J Eng Manufact 221(6):945–954

    Google Scholar 

  52. Yeong WY, Chua CK (2014) Bioprinting: principles and applications. World Scientific Publishing Co Inc, Singapore

    Google Scholar 

  53. Zhang J, Song B, Wei Q, Bourell D, Shi Y (2019) A review of selective laser melting of aluminum alloys: processing, microstructure, property and developing trends. J Mater Sci Technol 35(2):270–284

    Google Scholar 

  54. Tan C, Zhou K, Kuang T (2019) Selective laser melting of tungsten-copper functionally graded material. Mater Lett 237:328–331

    Google Scholar 

  55. Tan C, Zhou K, Ma W, Min L (2018) Interfacial characteristic and mechanical performance of maraging steel-copper functional bimetal produced by selective laser melting based hybrid manufacture. Mater Des 155:77–85

    Google Scholar 

  56. Yap CY, Chua CK, Dong ZL, Liu ZH, Zhang DQ, Loh LE, Sing SL (2015) Review of selective laser melting: materials and applications. Appl Phys Rev 2(4):041101

    Google Scholar 

  57. Sing SL, An J, Yeong WY, Wiria FE (2016) Laser and electron-beam powder-bed additive manufacturing of metallic implants: a review on processes, materials and designs. J Orthop Res 34(3):369–385

    Google Scholar 

  58. Terrazas CA, Gaytan SM, Rodriguez E, Espalin D, Murr LE, Medina F, Wicker RB (2014) Multi-material metallic structure fabrication using electron beam melting. Int J Adv Manufact Technol 71(1):33–45

    Google Scholar 

  59. Dutta B, Froes FS (2017) The additive manufacturing (AM) of titanium alloys. Met Powder Rep 72(2):96–106

    Google Scholar 

  60. Tan X, Kok Y, Tan YJ, Descoins M, Mangelinck D, Tor SB, Leong KF, Chua CK (2015) Graded microstructure and mechanical properties of additive manufactured Ti–6Al–4V via electron beam melting. Acta Mater 97:1–16

    Google Scholar 

  61. Biamino S, Penna A, Ackelid U, Sabbadini S, Tassa O, Fino P, Pavese M, Gennaro P, Badini C (2011) Electron beam melting of Ti–48Al–2Cr–2Nb alloy: microstructure and mechanical properties investigation. Intermetallics 19(6):776–781

    Google Scholar 

  62. Gaytan SM, Murr LE, Medina F, Martinez E, Lopez MI, Wicker RB (2009) Advanced metal powder based manufacturing of complex components by electron beam melting. Mater Technol 24(3):180–190

    Google Scholar 

  63. Dávila JL, Neto PI, Noritomi PY, Coelho RT, da Silva JVL (2020) Hybrid manufacturing: a review of the synergy between directed energy deposition and subtractive processes. Int J Adv Manufact Technol 110(11–12):3377–3390

    Google Scholar 

  64. Zhang R, Nagaraja KM, Bian N, Fisher E, Ahmadyar S, Bayazitoglu K, Lu H, Li W (2022) Experimental studies on fabricating functionally gradient material of stainless steel 316L-Inconel 718 through hybrid manufacturing: directed energy deposition and machining. Int J Adv Manufact Technol 120(11–12):7815–7826. https://doi.org/10.1007/s00170-022-09304-y

    Article  Google Scholar 

  65. Carroll BE, Otis RA, Borgonia JP, Suh JO, Dillon RP, Shapiro AA, Hofmann DC, Liu ZK, Beese AM (2016) Functionally graded material of 304L stainless steel and inconel 625 fabricated by directed energy deposition: characterization and thermodynamic modeling. Acta Mater 108:46–54

    Google Scholar 

  66. Svetlizky D, Das M, Zheng B, Vyatskikh AL, Bose S, Bandyopadhyay A, Schoenung JM, Lavernia EJ, Eliaz N (2021) Directed energy deposition (DED) additive manufacturing: physical characteristics, defects, challenges and applications. Mater Today 49:271–295

    Google Scholar 

  67. Liu W, DuPont JN (2003) Fabrication of functionally graded TiC/Ti composites by laser engineered net shaping. Scripta Mater 48(9):1337–1342

    Google Scholar 

  68. Selcuk C, Bond S, Woollin P (2010) Joining processes for powder metallurgy parts: a review. Powder Metall 53(1):7–11

    Google Scholar 

  69. Yu J, Rombouts M, Maes G, Motmans F (2012) Material properties of Ti6Al4 V parts produced by laser metal deposition. Phys Procedia 39:416–424

    Google Scholar 

  70. Duraisamy R, Kumar SM, Kannan AR, Shanmugam NS, Sankaranarayanasamy K (2021) Fatigue behavior of austenitic stainless steel 347 fabricated via wire arc additive manufacturing. J Mater Eng Perform 30(9):6844–6850

    Google Scholar 

  71. Wu B, Qiu Z, Pan Z, Carpenter K, Wang T, Ding D, Van Duin S, Li H (2020) Enhanced interface strength in steel-nickel bimetallic component fabricated using wire arc additive manufacturing with interweaving deposition strategy. J Mater Sci Technol 52:226–234

    Google Scholar 

  72. Chandrasekaran S, Hari S, Amirthalingam M (2020) Wire arc additive manufacturing of functionally graded material for marine risers. Mater Sci Eng A 792:139530

    Google Scholar 

  73. Kannan AR, Shanmugam NS, Ramkumar KD, Rajkumar V (2021) Studies on super duplex stainless steel manufactured by wire arc additive manufacturing. Trans Indian Inst Met 74:1673–1681

    Google Scholar 

  74. Nikam PP, Arun D, Ramkumar KD, Shanmugam NS (2021) Microstructure characterization and tensile properties of CMT-based wire plus arc additive manufactured ER2594. Mater Charact 172:110892

    Google Scholar 

  75. Pramod R, Kumar SM, Girinath B, Kannan AR, Kumar NP, Shanmugam NS (2020) Fabrication, characterisation, and finite element analysis of cold metal transfer–based wire and arc additive–manufactured aluminium alloy 4043 cylinder. Weld World 64(11):1905–1919

    Google Scholar 

  76. Kumar SM, Kannan AR, Pramod R, Shanmugam NS, Muthu SM, Dhinakaran V (2022) Microstructure and high temperature performance of 321 SS wall manufactured through wire+ arc additive manufacturing. Mater Lett 314:131913

    Google Scholar 

  77. Kannan AR, Kumar SM, Pramod R, Shanmugam NS, Vishnukumar M (2022) Microstructure and corrosion resistance of Ni-Cu alloy fabricated through wire arc additive manufacturing. Mater Lett 308:131262

    Google Scholar 

  78. Kannan AR, Kumar SM, Pramod R, Shanmugam NS, Vishnukumar M, Naveenkumar S (2021) Microstructural characterization and mechanical integrity of stainless steel 316L clad layers deposited via wire arc additive manufacturing for nuclear applications. Materialwiss Werkstofftech 52(6):617–623

    Google Scholar 

  79. Kannan AR, Kumar SM, Kumar NP, Shanmugam NS, Vishnu AS, Palguna Y (2020) Process-microstructural features for tailoring fatigue strength of wire arc additive manufactured functionally graded material of SS904L and Hastelloy C-276. Mater Lett 274:127968

    Google Scholar 

  80. Duraisamy R, Kumar SM, Kannan AR, Shanmugam NS, Sankaranarayanasamy K, Ramesh MR (2020) Tribological performance of wire arc additive manufactured 347 austenitic stainless steel under unlubricated conditions at elevated temperatures. J Manuf Process 56:306–321

    Google Scholar 

  81. Karpagaraj A, Baskaran S, Arunnellaiappan T, Kumar NR (2020) A review on the suitability of wire arc additive manufacturing (WAAM) for stainless steel 316. AIP Conf Proc 2247(1):050001

    Google Scholar 

  82. Kumar SM, Kannan AR, Kumar NP, Pramod R, Shanmugam NS, Vishnu AS, Channabasavanna SG (2021) Microstructural features and mechanical integrity of wire arc additive manufactured SS321/Inconel 625 functionally gradient material. J Mater Eng Perform 30:5692–5703

    Google Scholar 

  83. Madhuri N, Jayakumar V, Sathishkumar M (2021) Recent developments and challenges accompanying with wire arc additive manufacturing of Mg alloys: a review. Mater Today Proc 46:8573–8577

    Google Scholar 

  84. Wang J, Pan Z, Ma Y, Lu Y, Shen C, Cuiuri D, Li H (2018) Characterization of wire arc additively manufactured titanium aluminide functionally graded material: microstructure, mechanical properties and oxidation behaviour. Mater Sci Eng A 734:110–119

    Google Scholar 

  85. Li N, Liu W, Xiong H, Qin R, Huang S, Zhang G, Gao C (2019) In-situ reaction of Ti-Si-C composite powder and formation mechanism of laser deposited Ti6Al4V/(TiC+Ti3SiC2) system functionally graded material. Mater Des 183:108155

    Google Scholar 

  86. Meisner SN, Yakovlev EV, Semin VO, Meisner LL, Rotshtein VP, Neiman AA, D’yachenko F (2018) Mechanical behavior of Ti-Ta-based surface alloy fabricated on TiNi SMA by pulsed electron-beam melting of film/substrate system. Appl Surf Sci 437:217–226

    Google Scholar 

  87. Utyaganova V, Filippov A, Tarasov S, Shamarin N, Gurianov D, Vorontsov A, Chumaevskii A, Fortuna S, Savchenko N, Rubtsov V, Kolubaev E (2021) Characterization of AA7075/AA5356 gradient transition zone in an electron beam wire-feed additive manufactured sample. Mater Charact 172:110867

    Google Scholar 

  88. Osipovich KS, Astafurova EG, Chumaevskii AV, Kalashnikov KN, Astafurov SV, Maier GG, Melnikov EV, Moskvina VA, Panchenko MY, Tarasov SY, Rubtsov VE (2020) Gradient transition zone structure in “steel–copper” sample produced by double wire-feed electron beam additive manufacturing. J Mater Sci 55(22):9258–9272

    Google Scholar 

  89. DebRoy T, Wei HL, Zuback JS, Mukherjee T, Elmer JW, Milewski JO, Beese AM, Wilson-Heid AD, De A, Zhang W (2018) Additive manufacturing of metallic components–process, structure and properties. Prog Mater Sci 92:112–224

    Google Scholar 

  90. Gopan V, Wins KLD, Surendran A (2021) Innovative potential of additive friction stir deposition among current laser based metal additive manufacturing processes: a review. CIRP J Manuf Sci Technol 32:228–248

    Google Scholar 

  91. Mukhopadhyay A, Saha P (2020) Mechanical and microstructural characterization of aluminium powder deposit made by friction stir based additive manufacturing. J Mater Process Technol 281:116648

    Google Scholar 

  92. Li Y, He C, Wei J, Zhang Z, Qin G, Zhao X (2021) Correlation of local microstructures and mechanical properties of Al–Zn–Mg–Cu alloy build fabricated via underwater friction stir additive manufacturing. Mater Sci Eng, A 805:140590

    Google Scholar 

  93. Levy A, Miriyev A, Sridharan N, Han T, Tuval E, Babu SS, Dapino MJ, Frage N (2018) Ultrasonic additive manufacturing of steel: method, post-processing treatments and properties. J Mater Process Technol 256:183–189

    Google Scholar 

  94. Hehr A, Norfolk M (2019) A comprehensive review of ultrasonic additive manufacturing. Rapid Prototyp J 26(3):445–458

    Google Scholar 

  95. Wolcott PJ, Hehr A, Pawlowski C, Dapino MJ (2016) Process improvements and characterization of ultrasonic additive manufactured structures. J Mater Process Technol 233:44–52

    Google Scholar 

  96. Grigoriev S, Okunkova A, Sova A, Bertrand P, Smurov I (2015) Cold spraying: from process fundamentals towards advanced applications. Surf Coat Technol 268:77–84

    Google Scholar 

  97. Meng F, Yue S, Song J (2015) Quantitative prediction of critical velocity and deposition efficiency in cold-spray: a finite-element study. Scripta Mater 107:83–87

    Google Scholar 

  98. Cizek J, Man O, Roupcova P, Loke K, Dlouhy I (2015) Oxidation performance of cold spray Ti–Al barrier coated γ-TiAl intermetallic substrates. Surf Coat Technol 268:85–89

    Google Scholar 

  99. Yin S, Cavaliere P, Aldwell B, Jenkins R, Liao H, Li W, Lupoi R (2018) Cold spray additive manufacturing and repair: fundamentals and applications. Addit Manuf 21:628–650

    Google Scholar 

  100. Wu H, Liu S, Zhang Y, Liao H, Raoelison RN, Deng S (2021) New process implementation to enhance cold spray-based additive manufacturing. J Therm Spray Technol 30(5):1–10

    Google Scholar 

  101. Du W, Bai Q, Zhang B (2016) A novel method for additive/subtractive hybrid manufacturing of metallic parts. Proc Manufact 5:1018–1030

    Google Scholar 

  102. Gong M, Meng Y, Zhang S, Zhang Y, Zeng X, Gao M (2020) Laser-arc hybrid additive manufacturing of stainless steel with beam oscillation. Addit Manuf 33:101180

    Google Scholar 

  103. Wu D, Liu D, Niu F, Miao Q, Zhao K, Tang B, Bi G, Ma G (2020) Al–Cu alloy fabricated by novel laser-tungsten inert gas hybrid additive manufacturing. Addit Manuf 32:100954

    Google Scholar 

  104. Zeng G, Zahiri SH, Gulizia S, Chen Y, Chen XB, Cole I (2021) Hybrid additive manufacturing of biocompatible Ti–Ta composite structures for biomedical applications. J Mater Res 36(18):3679–3690

    Google Scholar 

  105. Kuryntsev SV (2018) The influence of pre-heat treatment on laser welding of T-joints of workpieces made of selective laser melting steel and cold rolled stainless steel. Opt Laser Technol 107:59–66

    Google Scholar 

  106. Ye ZP, Zhang ZJ, Jin X, Xiao MZ, Su JZ (2017) Study of hybrid additive manufacturing based on pulse laser wire depositing and milling. Int J Adv Manufact Technol 88(5–8):2237–2248

    Google Scholar 

  107. Zhang S, Zhang Y, Gao M, Wang F, Li Q, Zeng X (2019) Effects of milling thickness on wire deposition accuracy of hybrid additive/subtractive manufacturing. Sci Technol Weld Join 24(5):375–381

    Google Scholar 

  108. Liu C, Yan D, Tan J, Mai Z, Cai Z, Dai Y, Jiang M, Wang P, Liu Z, Li CC, Lao C (2020) Development and experimental validation of a hybrid selective laser melting and CNC milling system. Addit Manuf 36:101550

    Google Scholar 

  109. Wei C, Gu H, Zhang X, Chueh YH, Li L (2020) Hybrid ultrasonic and mini-motor vibration-induced irregularly shaped powder delivery for multiple materials additive manufacturing. Addit Manuf 33:101138

    Google Scholar 

  110. Yang Y, Li X (2003) Experimental and analytical study of ultrasonic micro powder feeding. J Phys D Appl Phys 36(11):1349

    Google Scholar 

  111. Wei C, Li L, Zhang X, Chueh YH (2018) 3D printing of multiple metallic materials via modified selective laser melting. CIRP Ann 67(1):245–248

    Google Scholar 

  112. Wei C, Gu H, Li Q, Sun Z, Chueh YH, Liu Z, Li L (2021) Understanding of process and material behaviours in additive manufacturing of Invar36/Cu10Sn multiple material components via laser-based powder bed fusion. Addit Manuf 37:101683

    Google Scholar 

  113. Zhang X, Wei C, Chueh YH, Li L (2019) An integrated dual ultrasonic selective powder dispensing platform for three-dimensional printing of multiple material metal/glass objects in selective laser melting. J Manuf Sci Eng 141(1):011003

    Google Scholar 

  114. Zhang X, Chueh Y, Wei C, Sun Z, Yan J, Li L (2020) Additive manufacturing of three-dimensional metal-glass functionally gradient material components by laser powder bed fusion with in situ powder mixing. Addit Manuf 33:101113

    Google Scholar 

  115. Chueh YH, Wei C, Zhang X, Li L (2020) Integrated laser-based powder bed fusion and fused filament fabrication for three-dimensional printing of hybrid metal/polymer objects. Addit Manuf 31:100928

    Google Scholar 

  116. Chueh YH, Zhang X, Wei C, Sun Z, Li L (2020) Additive manufacturing of polymer-metal/ceramic functionally graded composite components via multiple material laser powder bed fusion. J Manuf Sci Eng 142(5):051003

    Google Scholar 

  117. Yang S, Evans JRG (2007) Metering and dispensing of powder; the quest for new solid free forming techniques. Powder Technol 178(1):56–72

    Google Scholar 

  118. Nukala RK, Boyapally H, Slipper IJ, Mendham AP, Douroumis D (2010) The application of electrostatic dry powder deposition technology to coat drug-eluting stents. Pharm Res 27(1):72–81

    Google Scholar 

  119. Kumar A, Maji K (2021) Microstructure and chemical composition analysis of double wire arc additive manufactured bimetallic structure. J Mater Eng Perform 30(7):1–13

    Google Scholar 

  120. Reisgen U, Sharma R, Oster L (2019) Plasma multiwire technology with alternating wire feed for tailor-made material properties in wire and arc additive manufacturing. Metals 9(7):745

    Google Scholar 

  121. Filippov AV, Khoroshko ES, Shamarin NN, Savchenko NL, Moskvichev EN, Utyaganova VR, Kolubaev EA, Smolin AY, Tarasov SY (2021) Characterization of gradient CuAl–B4C composites additively manufactured using a combination of wire-feed and powder-bed electron beam deposition methods. J Alloys Compd 859:157824

    Google Scholar 

  122. Shen Q, Kong X, Chen X (2021) Fabrication of bulk Al-Co-Cr-Fe-Ni high-entropy alloy using combined cable wire arc additive manufacturing (CCW-AAM): microstructure and mechanical properties. J Mater Sci Technol 74:136–142

    Google Scholar 

  123. Qi Q, Wang HW, Zou CM, Wei ZJ (2012) Influence of matrix characteristics on tensile properties of in situ synthesized TiC/TA15 composite. Mater Sci Eng A 553:59–66

    Google Scholar 

  124. Wang D, Wang H, Sun S, Wang D, Wang H, Sun S, Zhu X, Tu G (2014) Fabrication and characterization of TiB2/TiC composites. Int J Refract Metal Hard Mater 45:95–101

    Google Scholar 

  125. Mahamood RM, Akinlabi ET (2015) Laser metal deposition of functionally graded Ti6Al4V/TiC. Mater Des 84:402–410

    Google Scholar 

  126. Li L, Wang J, Lin P, Liu H (2017) Microstructure and mechanical properties of functionally graded TiCp/Ti6Al4V composite fabricated by laser melting deposition. Ceram Int 43(18):16638–16651

    Google Scholar 

  127. Ratilal P, Madyira DM, Akinlabi ET, Babarinde TO (2018) Optimizing laser parameters of functional graded grade 5 titanium alloy (TI6AL4V) and titanium carbide (TIC). IOP Conf Ser Mater Sci Eng 413(1):012070

    Google Scholar 

  128. Sinyakova EA, Panin SV, Teresov AD (2019) Effect of pulsed electron beam irradiation on microstructure of TiC/Ti6Al4V composites fabricated by laser metal deposition. AIP Conf Proc 2167(1):020335

    Google Scholar 

  129. Builuk A, Kazachenok M, Martynov S (2019) Electron beam additive manufacturing of TiCx/Ti-6Al-4V composite electron beam additive manufacturing of TiCx/Ti-6Al-4V composite. AIP Conf Proc 2167(1):020039

    Google Scholar 

  130. Xu W, Brandt M, Sun S, Elambasseril J, Liu Q, Latham K, Xia K, Qian M (2015) Additive manufacturing of strong and ductile Ti–6Al–4V by selective laser melting via in situ martensite decomposition. Acta Mater 85:74–84

    Google Scholar 

  131. Xi L, Ding K, Gu D, Guo S, Cao M, Zhuang J, Lin K, Okulov I, Sarac B, Eckert J, Prashanth KG (2021) Interfacial structure and wear properties of selective laser melted Ti/(TiC+ TiN) composites with high content of reinforcements. J Alloys Compd 870:159436

    Google Scholar 

  132. Pouzet S, Peyre P, Gorny C, Castelnau O, Baudin T, Brisset F, Colin C, Gadaud P (2016) Additive layer manufacturing of titanium matrix composites using the direct metal deposition laser process. Mater Sci Eng A 677:171–181

    Google Scholar 

  133. Yang ZW, Fu LQ, Wang SL, Zhang M, Wang Y, Ma ZQ, Wang DP (2021) Balance of strength and plasticity of additive manufactured Ti-6Al-4V alloy by forming TiB whiskers with cyclic gradient distribution. Addit Manuf 39:101883

    Google Scholar 

  134. Lu L, Tian Y, Cai Y, Xin Y, Chen X, Zhang G, Han J (2021) Microstructure and mechanical properties of a functionally graded material from TA1 to Inconel 625 fabricated by dual wire+ arc additive manufacturing. Mater Lett 298:130010

    Google Scholar 

  135. Reichardt A, Dillon RP, Borgonia JP, Shapiro AA, McEnerney BW, Momose T, Hosemann P (2016) Development and characterization of Ti-6Al-4V to 304L stainless steel gradient components fabricated with laser deposition additive manufacturing. Mater Des 104:404–413

    Google Scholar 

  136. Bobbio LD, Bocklund B, Otis R, Borgonia JP, Dillon RP, Shapiro AA, Liu B, McEnerney ZK, Beese AM (2018) Characterization of a functionally graded material of Ti-6Al-4V to 304L stainless steel with an intermediate V section. J Alloys Compd 742:1031–1036

    Google Scholar 

  137. Li X, Pan C, Fu D, Wang M, Zhang Z, Qu S, Yang C (2021) Fabrication of highly dissimilar TC4/steel joint with V/Cu composite transition layer by laser melting deposition. J Alloy Compd 862:158319

    Google Scholar 

  138. Cui D, Lanfant B, Leparoux M, Favre S (2020) Additive Manufacturing of Ti-Nb dissimilar metals by laser metal deposition. In: International conference on additive manufacturing in products and applications, pp 96–111.

  139. Shang C, Wang C, Xu G, Li C, Yang G, You J (2020) Dissimilar jointing of TA15 to Inconel718 by laser additive manufacturing using Nb/Cu bilayer. J Manuf Process 55:153–160

    Google Scholar 

  140. Song D, Wang T, Zhu J, Jiang S, Xie Z (2020) Influence of welding sequences on the microstructure and mechanical properties of dual-pass electron beam welded Ti60/V/Cu/GH3128 joints. J Market Res 9(6):14168–14177

    Google Scholar 

  141. Li P, Li JL, Xiong JT, Zhang FS (2010) Structure and properties of diffusion bonded TA 2 to 1 Cr 18 Ni 9 Ti joints with Ni+ Nb composite interlayer Hangkong Cailiao Xuebao. J Aeronaut Mater 30(5):25–29

    Google Scholar 

  142. Hotz H, Zimmermann M, Greco S, Kirsch B, Aurich JC (2021) Additive manufacturing of functionally graded Ti-Al structures by laser-based direct energy deposition. J Manuf Process 68:1524–1534

    Google Scholar 

  143. Shah K, Haq IU, Shah SA, Shah K, Haq IU, Shah SA, Khan FU, Khan MT, Khan S (2014) Experimental study of direct laser deposition of Ti-6Al-4V and Inconel 718 by using pulsed parameters. Sci World J 2014:1–7

    Google Scholar 

  144. Onuike B, Bandyopadhyay A (2020) Functional bimetallic joints of Ti6Al4V to SS410. Addit Manuf 31:100931

    Google Scholar 

  145. He W, Wang JC, Tao LU, Liu CM (2021) Microstructure and mechanical properties of TA15/TC11 graded structural material by wire arc additive manufacturing process. Trans Nonferrous Metals Soc China 31(8):2323–2335

    Google Scholar 

  146. He B, Wu D, Pan J, Yang G (2021) Effect of heat treatment on microstructure and mechanical properties of laser deposited TA15/Ti2AlNb gradient composite structures. Vacuum 190:110309

    Google Scholar 

  147. Pang X, Xiong Z, Liu S, Misra D, Xiong Z, Li Z (2021) Laser melting deposition of CP-Ti/Ti–0.4 Ni graded material for structural applications. Metall Mater Trans A 52(11):4742–4748

    Google Scholar 

  148. Liu Y, Zhang Y (2020) Microstructure and mechanical properties of TA15-Ti2AlNb bimetallic structures by laser additive manufacturing. Mater Sci Eng A 795:140019

    Google Scholar 

  149. Chen H, Liu Z, Cheng X, Zou Y (2021) Laser deposition of graded γ-TiAl/Ti2AlNb alloys: microstructure and nanomechanical characterization of the transition zone. J Alloys Compd 875:159946

    Google Scholar 

  150. Kang N, Lin X, El Mansori M, Wang QZ, Lu JL, Coddet C, Huang WD (2020) On the effect of the thermal cycle during the directed energy deposition application to the in-situ production of a Ti-Mo alloy functionally graded structure. Addit Manuf 31:100911

    Google Scholar 

  151. Liu Z, Ma R, Xu G, Wang W, Liu J (2020) Laser additive manufacturing of bimetallic structure from Ti-6Al-4V to Ti-48Al-2Cr-2Nb via vanadium interlayer. Mater Lett 263:127210

    Google Scholar 

  152. Liu Y, Liu C, Liu W, Ma Y, Zhang C, Cai Q, Liu B (2018) Microstructure and properties of Ti/Al lightweight graded material by direct laser deposition. Mater Sci Technol 34(8):945–951

    Google Scholar 

  153. Ma R, Liu Z, Wang W, Xu G, Wang W (2020) Laser deposition melting of TC4/TiAl functionally graded material. Vacuum 177:109349

    Google Scholar 

  154. Zhou J, Li H, Yu Y, Li Y, Qian Y, Firouzian K, Lin F (2020) Fabrication of functionally graded materials from a single material by selective evaporation in electron beam powder bed fusion. Mater Sci Eng A 793:139827

    Google Scholar 

  155. Zhang YZ, Liu YT, Zhao XH, Tang YJ (2016) The interface microstructure and tensile properties of direct energy deposited TC11/Ti2AlNb dual alloy. Mater Des 110:571–580

    Google Scholar 

  156. Wu D, Liang X, Li Q, Jiang L (2010) Laser rapid manufacturing of stainless steel 316L/Inconel718 functionally graded materials: microstructure evolution and mechanical properties. Int J Opt 2010:1–5

    Google Scholar 

  157. Su Y, Chen B, Tan C, Song X, Feng J (2020) 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 283:116702

    Google Scholar 

  158. Meng W, Zhang W, Zhang W, Yin X, Cui B (2020) Fabrication of steel-Inconel functionally graded materials by laser melting deposition integrating with laser synchronous preheating. Opt Laser Technol 131:106451

    Google Scholar 

  159. Meng W, Zhang W, Yin X, Guo L, Cui B (2019) Additive fabrication of 316L/Inconel625/Ti6Al4V functionally graded materials by laser synchronous preheating. Int J Adv Manufact Technol 104(5):2525–2538

    Google Scholar 

  160. Kannan AR, Kumar SM, Pramod R, Kumar NP, Shanmugam NS, Palguna Y (2020) Microstructure and mechanical properties of wire arc additive manufactured bi-metallic structure. Sci Technol Weld Join 26(1):47–57

    Google Scholar 

  161. Rajendran S, Kannan AR, Suresha B, Shanmugam NS (2022) Studies on the fatigue performance of wire and arc additive manufactured SS 904L, In: Proceedings of the international conference on industrial and manufacturing systems (CIMS-2020), Springer International Publishing, pp 343–352

  162. Ferreira AA, Emadinia O, Cruz JM, Reis AR, Vieira MF (2021) Inconel 625/AISI 413 stainless steel functionally graded material produced by direct laser deposition. Materials 14(19):5595

    Google Scholar 

  163. Chen B, Su Y, Xie Z, Tan C, Feng J (2020) Development and characterization of 316L/Inconel625 functionally graded material fabricated by laser direct metal deposition. Opt Laser Technol 123:105916

    Google Scholar 

  164. Feenstra DR, Molotnikov A, Birbilis N (2020) Effect of energy density on the interface evolution of stainless steel 316L deposited upon INC 625 via directed energy deposition. J Mater Sci 55(27):13314–13328

    Google Scholar 

  165. Senthil TS, Ramesh Babu S, Puviyarasan M, Dhinakaran V (2021) Mechanical and microstructural characterization of functionally graded Inconel 825-SS316L fabricated using wire arc additive manufacturing. J Mater Res Technol 15:661–669

    Google Scholar 

  166. Li P, Gong Y, Xu Y, Qi Y, Sun Y, Zhang H (2019) Inconel-steel functionally bimetal materials by hybrid directed energy deposition and thermal milling: microstructure and mechanical properties. Archiv Civil Mech Eng 19(3):820–831

    Google Scholar 

  167. Popovich VA, Borisov EV, Popovich AA, Sufiiarov VS, Masaylo DV, Alzina L (2017) Functionally graded Inconel 718 processed by additive manufacturing: crystallographic texture, anisotropy of microstructure and mechanical properties. Mater Des 114:441–449

    Google Scholar 

  168. Dubey A, Jaiswal S, Haldar S, Roy P, Lahiri D (2020) Functionally gradient magnesium-based composite for temporary orthopaedic implant with improved corrosion resistance and osteogenic properties. Biomed Mater 16(1):015017

    Google Scholar 

  169. Staiger MP, Pietak AM, Huadmai J, Dias G (2006) Magnesium and its alloys as orthopedic biomaterials: a review. Biomaterials 27(9):1728–1734

    Google Scholar 

  170. Witte F, Hort N, Vogt C, Cohen S, Kainer KU, Willumeit R, Feyerabend F (2008) Degradable biomaterials based on magnesium corrosion. Curr Opin Solid State Mater Sci 12(5–6):63–72

    Google Scholar 

  171. Waizy H, Diekmann J, Weizbauer A, Reifenrath J, Bartsch I, Neubert V, Schavan R, Windhagen H (2014) In vivo study of a biodegradable orthopedic screw (MgYREZr-alloy) in a rabbit model for up to 12 months. J Biomater Appl 28(5):667–675

    Google Scholar 

  172. Huehnerschulte TA, Reifenrath J, Rechenberg BV, Dziuba D, Seitz JM, Bormann D, Windhagen H, Lindenberg AM (2012) In vivo assessment of the host reactions to the biodegradation of the two novel magnesium alloys ZEK100 and AX30 in an animal model. Biomed Eng Online 11(1):1–20

    Google Scholar 

  173. Sealy MP, Guo YB, Liu JF, Li C (2016) Pulsed laser cutting of magnesium-calcium for biodegradable stents. Procedia CIRP 42:67–72

    Google Scholar 

  174. Charpentier E, Barna A, Guillevin L, Juliard JM (2015) Fully bioresorbable drug-eluting coronary scaffolds: a review. Arch Cardiovasc Dis 108(6–7):385–397

    Google Scholar 

  175. Shuai C, He C, Xu L, Li Q, Chen T, Yang Y, Peng S (2018) Wrapping effect of secondary phases on the grains: increased corrosion resistance of Mg–Al alloys. Virtual Phys Prototyp 13(4):292–300

    Google Scholar 

  176. Cao X, Jahazi M, Immarigeon JP, Wallace W (2006) A review of laser welding techniques for magnesium alloys. J Mater Process Technol 171(2):188–204

    Google Scholar 

  177. Liu L (2010) Welding and joining of magnesium alloys, Woodhead Publishing Limited

  178. Watanabe Y, Sato R, Kim IS, Miura S, Miura H (2005) Functionally graded material fabricated by a centrifugal method from ZK60A magnesium alloy. Mater Trans 46(5):944–949

    Google Scholar 

  179. Yang C, Wu C, Shi L (2020) Modeling the dissimilar material flow and mixing in friction stir welding of aluminum to magnesium alloys. J Alloys Compd 843:156021

    Google Scholar 

  180. Satyanarayana MHMNK, Srinivas PNS (2019) Experimental investigation of mechanical properties of Al-SiC-MgO2 FGM. Int J Sci Res Eng Trends 5(3):1030–1033

    Google Scholar 

  181. Miranda R (2014) Surface reinforcements of light alloys: surface modification by solid state processing. Elsevier, Amsterdam, pp 113–152

    Google Scholar 

  182. Kurzynowski T, Pawlak A, Smolina I (2020) The potential of SLM technology for processing magnesium alloys in aerospace industry. Archiv Civil Mech Eng 20(1):1–13

    Google Scholar 

  183. Liu S, Guo H (2020) Influence of hot isostatic pressing (HIP) on mechanical properties of magnesium alloy produced by selective laser melting (SLM). Mater Lett 265:127463

    Google Scholar 

  184. Taltavull C, Torres B, López AJ, Rodrigo P, Otero E, Rams J (2012) Selective laser surface melting of a magnesium-aluminium alloy. Mater Lett 85:98–101

    Google Scholar 

  185. Gheysarian A, Honarpisheh M (2021) Experimental and numerical investigation of process parameters on the residual stresses in the Al-Cu FGM materials. Exp Tech 45(5):1–12

    Google Scholar 

  186. Onuike B, Heer B, Bandyopadhyay A (2018) Additive manufacturing of Inconel 718-Copper alloy bimetallic structure using laser engineered net shaping (LENS™). Addit Manuf 21:133–140

    Google Scholar 

  187. Tan C, Chew Y, Bi G, Wang D, Ma W, Yang Y, Zhou K (2021) Additive manufacturing of steel–copper functionally graded material with ultrahigh bonding strength. J Mater Sci Technol 72:217–222

    Google Scholar 

  188. Zhang X, Pan T, Chen Y, Li L, Zhang Y, Liou F (2021) Additive manufacturing of copper-stainless steel hybrid components using laser-aided directed energy deposition. J Mater Sci Technol 80:100–116

    Google Scholar 

  189. Wei C, Liu L, Cao H, Zhong X, Xu X, Gu Y, Cheng D, Huang Y, Li Z, Guo W, Liu Z (2022) Cu10Sn to Ti6Al4V bonding mechanisms in laser-based powder bed fusion multiple material additive manufacturing with different build strategies. Addit Manuf 51:102588

    Google Scholar 

  190. Pan T, Zhang X, Yamazaki T, Sutton A, Cui W, Li L, Liou F (2020) Characteristics of Inconel 625-copper bimetallic structure fabricated by directed energy deposition. Int J Adv Manufact Technol 109(5):1261–1274

    Google Scholar 

  191. Li L, Zhang X, Cui W, Liou F, Deng W, Li W (2020) Temperature and residual stress distribution of FGM parts by DED process: modeling and experimental validation. Int J Adv Manufact Technol 109(1):451–462

    Google Scholar 

  192. Mao S, Zhang DZ, Ren Z, Fu G, Ma X (2022) Effects of process parameters on interfacial characterization and mechanical properties of 316L/CuCrZr functionally graded material by selective laser melting. J Alloy Compd 899:163256

    Google Scholar 

  193. Chen J, Yang Y, Song C, Zhang M, Wu S, Wang D (2019) Interfacial microstructure and mechanical properties of 316L/CuSn10 multi-material bimetallic structure fabricated by selective laser melting. Mater Sci Eng, A 752:75–85

    Google Scholar 

  194. Liu ZH, Zhang DQ, Sing SL, Chua CK, Loh LE (2014) Interfacial characterization of SLM parts in multi-material processing: Metallurgical diffusion between 316L stainless steel and C18400 copper alloy. Mater Charact 94:116–125

    Google Scholar 

  195. Sing SL, Lam LP, Zhang DQ, Liu ZH, Chua CK (2015) Interfacial characterization of SLM parts in multi-material processing: Intermetallic phase formation between AlSi10Mg and C18400 copper alloy. Mater Charact 107:220–227

    Google Scholar 

  196. Zhang M, Yang Y, Wang D, Song C, Chen J (2019) Microstructure and mechanical properties of CuSn/18Ni300 bimetallic porous structures manufactured by selective laser melting. Mater Des 165:107583

    Google Scholar 

  197. Al-Jamal OM, Hinduja S, Li L (2008) Characteristics of the bond in Cu–H13 tool steel parts fabricated using SLM. CIRP Ann 57(1):239–242

    Google Scholar 

  198. Pei E, Loh GH, Harrison D, Almeida HDA, Verona MDM, Paz R (2017) study of 4D printing and functionally graded additive manufacturing. Assem Autom 37(2):147–153

    Google Scholar 

  199. Hendrikson WJ, Rouwkema J, Clementi F, Van Blitterswijk CA, Farè S, Moroni L (2017) Towards 4D printed scaffolds for tissue engineering: exploiting 3D shape memory polymers to deliver time-controlled stimulus on cultured cells. Biofabrication 9(3):031001

    Google Scholar 

  200. Joe Lopes A, MacDonald E, Wicker RB (2012) Integrating stereolithography and direct print technologies for 3D structural electronics fabrication. Rapid Prototyp J 18(2):129–143

    Google Scholar 

  201. Bodaghi M, Damanpack AR, Liao WH (2017) Adaptive metamaterials by functionally graded 4D printing. Mater Des 135:26–36

    Google Scholar 

  202. Gao B, Yang Q, Zhao X, Jin G, Ma Y, Xu F (2016) 4D bioprinting for biomedical applications. Trends Biotechnol 34(9):746–756

    Google Scholar 

  203. Kaushal S, Gupta D, Bhowmick H (2017) Investigation of dry sliding wear behavior of Ni–SiC microwave cladding. J Tribol 139(4):041603

    Google Scholar 

  204. Salehi M, Maleksaeedi S, Nai MLS, Gupta M (2019) Towards additive manufacturing of magnesium alloys through integration of binderless 3D printing and rapid microwave sintering. Addit Manuf 29:100790

    Google Scholar 

  205. El Khaled D, Novas N, Gazquez JA, Agugliaro FM (2018) Microwave dielectric heating: Applications on metals processing. Renew Sustain Energy Rev 82:2880–2892

    Google Scholar 

  206. Martina F, Colegrove PA, Williams SW, Meyer J (2015) Microstructure of interpass rolled wire + Arc additive manufacturing Ti-6Al-4V components. Metall and Mater Trans A 46(12):6103–6118

    Google Scholar 

  207. Marinelli G, Martina F, Ganguly S, Williams S (2020) Grain refinement in an unalloyed tantalum structure by combining Wire+Arc additive manufacturing and vertical cold rolling. Addit Manuf 32:101009

    Google Scholar 

  208. Martina F, Roy MJ, Szost BA, Terzi S, Colegrove PA, Williams SW, Withers PJ, Meyer J, Hofmann M (2016) Residual stress of as-deposited and rolled wire+ arc additive manufacturing Ti–6Al–4V components. Mater Sci Technol 32(14):1439–1448

    Google Scholar 

  209. Almangour B, Yang JM (2016) Improving the surface quality and mechanical properties by shot-peening of 17–4 stainless steel fabricated by additive manufacturing. Mater Des 110:914–924

    Google Scholar 

  210. Ding K, Ye L (2006) Simulation methodology. Elsevier, Laser Shock Peening, pp 47–72

    Google Scholar 

  211. Birnbaum AJ, Vikelic S, Lawrence Yao Y (2010) Advances in laser-induced plastic deformation processes, advances in laser materials processing. Elsevier, Amsterdam, pp 535–572

    Google Scholar 

  212. Wu LJ, Luo KY, Liu Y, Cui CY, Xue W, Lu JZ (2018) Effects of laser shock peening on the micro-hardness, tensile properties, and fracture morphologies of CP-Ti alloy at different temperatures. Appl Surf Sci 431:122–134

    Google Scholar 

  213. Yan K, Wei P, Ren F, He W, Sun Q (2019) Enhance fatigue resistance of nanocrystalline NiTi by laser shock peening. Shape Memory Superelasticity 5(4):436–443

    Google Scholar 

  214. Malaki M, Ding H (2015) A review of ultrasonic peening treatment. Mater Des 87:1072–1086

    Google Scholar 

  215. Liu Y, Wang D, Deng C, Xia L, Huo L, Wang L, Gong B (2014) Influence of re-ultrasonic impact treatment on fatigue behaviors of S690QL welded joints. Int J Fatigue 66:155–160

    Google Scholar 

  216. Zohrevand M, Khafri MA, Forouzan F, Vuorinen E (2021) Internal stress relief and microstructural evolution by ultrasonic treatment of austeno-ferritic 2205 duplex stainless steel. Mater Sci Eng A 815:141290

    Google Scholar 

  217. Benzing J, Hrabe N, Quinn T, White R, Rentz R, Ahlfors M (2019) Hot isostatic pressing (HIP) to achieve isotropic microstructure and retain as-built strength in an additive manufacturing titanium alloy (Ti-6Al-4V). Mater Lett 257:126690

    Google Scholar 

  218. Leriche A, Hampshire S, Cambier F (2021) Control of the microstructure in ceramics, encyclopedia of materials: technical ceramics and glasses. Elsevier, Amsterdam, pp 349–366

    Google Scholar 

  219. Heaney DF, Binet C (2019) Hot isostatic pressing (HIP) of metal injection molding (MIM). In: Handbook of Metal Injection Molding, Elsevier, (2019), pp 195–202

  220. Namara KM, Butler J, Gandhi AA, Tofail SAM (2017) Powder metallurgical processing of NiTi using spark plasma sintering. In: Comprehensive Materials Finishing, Elsevier, pp 336–346

  221. Fujikawa T, Manabe Y (2013) Recent advances in HIP technology and atmosphere control in HIP treatment. Elsevier, Handbook of Advanced Ceramics, pp 1203–1211

    Google Scholar 

  222. Bernal MHB (2004) Hot isostatic pressing (HIP) technology and its applications to metals and ceramics. J Mater Sci 39(21):6399–6420

    Google Scholar 

  223. Berglund T, Östlund M (2016) Impact toughness for PM HIP 316L at cryogenic temperatures, ASME Pressure Vessels and Piping Conference, 50428,V06AT06A014

  224. Pramod R, Kumar SM, Kannan AR, Shanmugam NS, Tangestani R (2022) Fabrication of gas metal arc welding based wire plus arc additive manufactured 347 stainless steel structure: behavioral analysis through experimentation and finite element method. Met Mater Int 28(1):307–321

    Google Scholar 

  225. Geng Y, Harrison NM (2021) Functionally graded bimodal Ti6Al4V fabricated by powder bed fusion additive manufacturing: crystal plasticity finite element modelling. Mater Sci Eng, A 804:140748

    Google Scholar 

  226. Lu LX, Sridhar N, Zhang YW (2018) Phase field simulation of powder bed-based additive manufacturing. Acta Mater 144:801–809

    Google Scholar 

  227. Gu H, Wei C, Li L, Han Q, Setchi R, Ryan M, Li Q (2020) Multi-physics modelling of molten pool development and track formation in multi-track, multi-layer and multi-material selective laser melting. Int J Heat Mass Transf 151:119458

    Google Scholar 

  228. Tapia G, Elwany A (2014) A review on process monitoring and control in metal-based additive manufacturing. J Manuf Sci Eng 136(6):060801

    Google Scholar 

  229. He W, Shi W, Li J, Xie H (2019) In-situ monitoring and deformation characterization by optical techniques Part I: laser-aided direct metal deposition for additive manufacturing. Opt Lasers Eng 122:74–88

    Google Scholar 

  230. Raghavan N, Simunovic S, Dehoff R, Plotkowski A, Turner J, Kirka M, Babu S (2017) Localized melt-scan strategy for site specific control of grain size and primary dendrite arm spacing in electron beam additive manufacturing. Acta Mater 140:375–387

    Google Scholar 

  231. Costantini M, Jaroszewicz J, Kozoń Ł, Szlązak K, Święszkowski W, Garstecki P, Stubenrauch C, Barbetta A, Guzowski J (2019) 3D-printing of functionally graded porous materials using on-demand reconfigurable microfluidics. Angew Chem Int Ed 58(23):7620–7625

    Google Scholar 

  232. Li W, Martin AJ, Kroehler B, Henderson A, Huang T, Watts J, Hilmas GE, Leu MC (2018) Fabricating functionally graded materials by ceramic on-demand extrusion with dynamic mixing. In: Proceedings of the 29th annual international solid freeform fabrication symposium (2018, Austin, TX), University of Texas at Austin, pp 1087–1099

  233. Duraisamy R, Kumar SM, Kannan AR, Shanmugam NS, Sankaranarayanasamy K (2021) Reliability and sustainability of wire arc additive manufactured plates using ER 347 wire-mechanical and metallurgical perspective. Proc Inst Mech Eng C J Mech Eng Sci 235(10):1860–1871

    Google Scholar 

  234. Kannan AR, Shanmugam NS, Rajkumar V, Vishnukumar M (2020) Insight into the microstructural features and corrosion properties of wire arc additive manufactured super duplex stainless steel (ER2594). Mater Lett 270:127680

    Google Scholar 

  235. Kenel C, Grolimund D, Li X, Panepucci E, Samson VA, Sanchez DF, Marone F, Leinenbach C (2017) In situ investigation of phase transformations in Ti-6Al-4V under additive manufacturing conditions combining laser melting and high-speed micro-X-ray diffraction. Sci Rep 7(1):1–10

    Google Scholar 

  236. Pesach A, Tiferet E, Vogel SC, Chonin M, Diskin A, Zilberman L, Rivin O, Yeheskel O, El’ad NC (2018) Texture analysis of additively manufactured Ti-6Al-4V using neutron diffraction. Addit Manuf 23:394–401

    Google Scholar 

  237. Nycz A, Lee Y, Noakes M, Ankit D, Masuo C, Simunovic S, Bunn J, Love L, Oancea V, Payzant A, Fancher CM (2021) Effective residual stress prediction validated with neutron diffraction method for metal large-scale additive manufacturing. Mater Des 205:109751

    Google Scholar 

  238. Dehoff RR, Kirka MM, Sames WJ, Bilheux H, Tremsin AS, Lowe LE, Babu SS (2015) Site specific control of crystallographic grain orientation through electron beam additive manufacturing. Mater Sci Technol 31(8):931–938

    Google Scholar 

  239. Wang Q, Zhang S, Zhang C, Wu C, Wang J, Chen J, Sun Z (2017) Microstructure evolution and EBSD analysis of a graded steel fabricated by laser additive manufacturing. Vacuum 141:68–81

    Google Scholar 

  240. Rudolph JP, Emmelmann C (2017) A cloud-based platform for automated order processing in additive manufacturing. Procedia CIRP 63:412–417

    Google Scholar 

  241. Zhang Z, Wen G, Chen S (2016) Multisensory data fusion technique and its application to welding process monitoring, IEEE Workshop on advanced robotics and its social impacts (ARSO), pp 294–298

  242. Wang Y, Zheng P, Peng T, Yang H, Zou J (2020) Smart additive manufacturing: current artificial intelligence-enabled methods and future perspectives. SCIENCE CHINA Technol Sci 63:1600–1611

    Google Scholar 

  243. Jin Z, Zhang Z, Gu GX (2020) Automated real-time detection and prediction of interlayer imperfections in additive manufacturing processes using artificial intelligence. Adv Intell Syst 2(1):1900130

    Google Scholar 

  244. Wang C, Tan XP, Tor SB, Lim CS (2020) Machine learning in additive manufacturing: State-of-the-art and perspectives. Addit Manuf 36:101538

    Google Scholar 

  245. Scime L, Beuth J (2019) Using machine learning to identify in-situ melt pool signatures indicative of flaw formation in a laser powder bed fusion additive manufacturing process. Addit Manuf 25:151–165

    Google Scholar 

  246. Kumar R, Kumar M, Chohan JS (2020) The role of additive manufacturing for biomedical applications: a critical review. J Manuf Process 64:828–850

    Google Scholar 

  247. Abdulhameed O, Al-Ahmari A, Ameen W, Mian SH (2019) Additive manufacturing: challenges, trends, and applications. Adv Mech Eng 11(2):1–27

    Google Scholar 

  248. Jaiswal P, Patel J, Rai R (2018) Build orientation optimization for additive manufacturing of functionally graded material objects. Int J Adv Manufact Technol 96(1–4):223–235

    Google Scholar 

  249. Cunningham CR, Flynn JM, Shokrani A, Dhokia V, Newman ST (2018) Invited review article: strategies and processes for high quality wire arc additive manufacturing. Addit Manuf 22:672–686

    Google Scholar 

  250. Rajkumar V, Vishnukumar M, Sowrirajan M, Kannan AR (2022) Microstructure, mechanical properties and corrosion behaviour of Incoloy 825 manufactured using wire arc additive manufacturing. Vacuum 203:111324

    Google Scholar 

  251. Kannan AR, Palguna Y, Korla R, Kumar SM, Pramod R, Shanmugam NS (2023) Hot tensile deformation and fracture behavior of wire arc additive manufactured Hastelloy C-276. Weld World. https://doi.org/10.1007/s40194-023-01462-1

    Article  Google Scholar 

  252. Vaezi M, Drescher P, Seitz H (2020) Beamless metal additive manufacturing. Materials 13(4):922

    Google Scholar 

  253. Yang SW, Yoon J, Lee H, Shim DS (2022) Defect of functionally graded material of inconel 718 and STS 316L fabricated by directed energy deposition and its effect on mechanical properties. J Market Res 17:478–497

    Google Scholar 

  254. Korkmaz ME, Gupta MK, Robak G, Moj K, Krolczyk GM, Kuntoğlu M (2022) Development of lattice structure with selective laser melting process: a state of the art on properties, future trends and challenges. J Manuf Process 81:1040–1063

    Google Scholar 

  255. Maskery I, Aboulkhair NT, Aremu AO, Tuck CJ, Ashcroft IA, Wildman RD, Hague RJM (2016) A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting. Mater Sci Eng A 670:264–274

    Google Scholar 

  256. Hällgren S, Pejryd L, Ekengren J (2016) Additive manufacturing and high speed machining -cost comparison of short lead time manufacturing methods. Procedia CIRP 50:384–389

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology, Tiruchirappalli, Tamil Nadu, 620015, India

    K. Sanjeeviprakash & N. Siva Shanmugam

  2. Department of Mechanical Engineering, Hanyang University, 55, Hanyangdaehak-Ro, Ansan, 15588, Gyeonggi-do, Republic of Korea

    A. Rajesh Kannan

Authors
  1. K. Sanjeeviprakash
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. Rajesh Kannan
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. N. Siva Shanmugam
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to N. Siva Shanmugam.

Ethics declarations

Conflict of interest

No potential conflict of interest was reported by the author(s).

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sanjeeviprakash, K., Kannan, A.R. & Shanmugam, N.S. Additive manufacturing of metal-based functionally graded materials: overview, recent advancements and challenges. J Braz. Soc. Mech. Sci. Eng. 45, 241 (2023). https://doi.org/10.1007/s40430-023-04174-1

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s40430-023-04174-1

Keywords

Search

Navigation