Dissimilar metal additive manufacturing of aluminum-steel (AlFe) components offers many opportunities for achieving effective structural lightweighting and multi-functionalities. However, just like direct welding of aluminum alloys to steels, the formation of detrimental intermetallic compounds (IMCs) at the AlFe bimetallic interface has been seen as the major challenge. One recent development in understanding nanoscale shear localization induced alloy amorphization at the AlFe interface has provided a physical basis for developing a modified friction stir additive manufacturing (FSAM) process. This study shows that the modified FSAM is an effective solution for mitigating detrimental IMCs through the development of the nanoscale amorphous phase between the deposited aluminum alloy and steel substrate. The results show that the formation of the nanoscale amorphous metal at the AlFe bimetallic interface leads to the development of ductile fracture features within the aluminum layer in the mechanical tests. Compared to the existing FSAM, the modified FSAM enables a more robust and cost-effective manufacture of AlFe bimetallic structures without introducing detrimental IMCs.

铝钢 (Al Fe) 部件的异种金属增材制造为实现有效的结构轻量化和多功能性提供了许多机会。然而，就像铝合金与钢的直接焊接一样，在铝铁双金属界面处形成有害的金属间化合物 (IMC)被视为主要挑战。了解纳米级剪切局部化诱导合金在 Al 处非晶化的最新进展Fe 界面为开发改进的搅拌摩擦增材制造 (FSAM) 工艺提供了物理基础。该研究表明，改性 FSAM 是通过在沉积铝合金和钢基材之间形成纳米级非晶相来减轻有害 IMC 的有效解决方案。结果表明，在力学测试中，Al Fe 双金属界面处纳米级非晶金属的形成导致铝层内韧性断裂特征的发展。与现有的 FSAM 相比，改进后的 FSAM 能够在不引入有害 IMC 的情况下，更稳健、更具成本效益地制造 Al Fe 双金属结构。