Multi-material 3D printing: the role of substrate-based synthesis

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Abstract

Multimaterial 3D printing by the substrate-based synthesis (SBS) method is a promising approach to obtain the products with the locally variable properties. However, the processing limits associated with various differences in the physicochemical properties of the materials being combined and the lack of a systematic classification hinder the development of this area. A new classification of multi-materials for SBS has been developed that includes three groups: homogeneous alloys (based on a single metal), dissimilar weldable alloys, and dissimilar non-weldable alloys. The features of transition zones for seven systems (VT6/VT1-0, AlSi10Mg/Al-Si-Mg-Cu, 316L/FeNi36, VZh159/BrKhTsrT V, Ti6Al4V/Inconel 718, 316L/NiTi) have been studied. It has been established that the number of defects, microstructure, and phase composition of the transition zone are determined by the type of alloy combination. The developed classification allows us to systematize the research works, optimize printing parameters, including of the laser tools, and predict any possible problems occurred when developing new multi-material systems.

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About the authors

Arseniy V. Repnin

Peter the Great Saint-Petersburg Polytechnic University

Author for correspondence.
Email: repnin_arseniy@mail.ru
ORCID iD: 0009-0001-3157-3317

Cand.of Sc. (Tech.), engineer of the laboratory “Synthesis of new materials and structures”

Russian Federation, Saint-Petersburg

Evgeny V. Borisov

Peter the Great Saint-Petersburg Polytechnic University

Email: evgenii.borisov@icloud.com
ORCID iD: 0000-0003-2464-6706

Cand.of Sc. (Tech.), leading research fellow of the laboratory “Synthesis of new materials and structures”

Russian Federation, Saint-Petersburg

Anatoly A. Popovich

Peter the Great Saint-Petersburg Polytechnic University

Email: director@immet.spbstu.ru
ORCID iD: 0000-0002-5974-6654

Dr.of Sc. (Tech.), professor, director of the Institute of Mechanical Engineering, Materials and Transport

Russian Federation, Saint-Petersburg

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Supplementary files

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2. Fig. 1. Examples of multi-material products obtained by the SBS method: a) multi-material combustion chamber for a liquid rocket engine, b) multi-material gear

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3. Fig. 2. Porosity occurrence in the transition zone of multi-materials [21]: a) porosity formation in the case of excess energy, b) porosity formation in the case of insufficient energy

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4. Fig. 3. Crack formation in the transition zone of multi-materials [25]: a) crack formation due to the availability of embrittling intermetallides, b) absence of cracks due to the use of a transition layer

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5. Fig. 4. Change in the transition zone width [21, 25]: a) sharp transition from one alloy to another, b–c) gradient transition from one alloy to another

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6. Fig. 5. Inefficient use of transition layers to reduce the defects (316L/NiTi multi-material with a transition layer made of high-density oxide – CoCrFeNiMn) [23]

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7. Fig. 6. Classification of multi-material additive manufacturing for the SBS process

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Copyright (c) 2025 Repnin A.V., Borisov E.V., Popovich A.A.