Joining multi-materials with complex geometries is a promising method to achieve multi-functional components that overcome traditional manufacturing limitations. Selective laser melting (SLM), also known as laser powder bed fusion (LPBF), is an additive manufacturing (AM) technique that enables the production of complex geometries, but it typically operates using a single material and a substrate made of the same material. Here, we show that the SLM technique can be used to join dissimilar printed materials (pure Al, pure Cu, and 50 at. pct Al-50 at. pct Cu mixed powders, respectively) with a typical stainless steel (316L) substrate. We investigate the interfacial characteristics between dissimilar materials processed at various laser energy densities and the feasibility of in situ alloying during the SLM process. Moreover, we employ the finite element method (FEM) to visualize the melting behaviors of Al and Cu powders upon laser irradiation. Pure Al and Cu powders join the stainless steel with distinct characteristics through diffusion and melting. We also produce an Al-Cu alloy with uniformly distributed elements by the SLM processing of Al-Cu mixed powders. Our study demonstrates the feasibility of joining dissimilar materials and in situ alloying in the SLM process.

将具有复杂几何形状的多材料连接在一起是一种有希望的方法，可以实现克服传统制造限制的多功能组件。选择性激光熔化（SLM），也称为激光粉末床熔合（LPBF），是一种增材制造（AM）技术，能够生产复杂的几何形状，但通常使用单一材料和由相同材料制成的基板进行操作。在这里，我们表明SLM技术可用于将不同的印刷材料（分别为纯Al，纯Cu和50 at。pct Al-50 at。pct铜混合粉末）与典型的不锈钢（316L）基材连接在一起。我们研究了在不同激光能量密度下加工的异种材料之间的界面特性以及原位可行性在SLM过程中合金化。此外，我们采用有限元方法（FEM）来观察激光辐照下Al和Cu粉末的熔化行为。纯的Al和Cu粉末通过扩散和熔化而结合在一起，具有独特的特性。我们还通过SLM处理Al-Cu混合粉末来生产元素均匀分布的Al-Cu合金。我们的研究证明了在SLM工艺中加入异种材料和原位合金化的可行性。