| Summary: | To achieve high-quality 3D printing of multi-metal (alloy) materials, the main challenge is how to obtain strong bonding strength between the dissimilar materials in additive manufacturing. The presence of thermal incompatibility during material melting, cooling, and solidification stages results in the formation of defects like pores, cracks, and brittle intermediate phases. These defects compromise the quality of the bonded interface. The current study aims to investigate the interfacial hardness between CoCrMo/IN625 through experimental and computational simulation approaches to identify the optimal machining parameters for reliable and durable production of multi-metal parts. The simulated molten pool characteristics are analysed and compared with our experimental data. The findings indicate that when the volumetric energy density (Ev) is equal to or less than 20 J/mm3, there is insufficient diffusion due to inadequate microfluidic forces between the two metals. Consequently, the high-hardness CoCrMo acts as a supportive element leading to a significant increase in interface hardness. As the volumetric energy density increases further, strong recoil pressure disrupts the melt pool within the microfluidic system, facilitating complete diffusion between both metallic substances. This leads to a decrease in interface hardness due to dilution caused by full diffusion of high-hardness CoCrMo with low-hardness IN625 alloy material.
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