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<p>The key to heterogeneous structure additive manufacturing lies in the fusion of interfaces. In this paper, the forming characteristics, microstructures, and mechanical properties of Al/Mg dissimilar metals were investigated during wire-arc directed energy deposition based on the cold metal transfer (CMT) process. The results show that heat input affects the Al/Mg bimetallic structure’s geometry, porosity, and microstructures at the interface, with a specific emphasis on the intermetallic compounds (IMCs) formation, and the subsequent impact on the joint. The interface reaction zone is composed of Mg<sub>17</sub>Al<sub>12</sub> + δ-Mg eutectic layer/ Mg<sub>17</sub>Al<sub>12</sub> layer/ Mg<sub>2</sub>Al<sub>3</sub> layer. Combined with thermodynamic calculations, the formation mechanism of compounds was clarified. The maximum compression–shear strength of the joints reached 48.45&#xa0;MPa. Fracture analysis indicates that the crack propagates along the Mg<sub>2</sub>Al<sub>3</sub> layer and eventually causes the joint to break. Experimental calculations also confirm that the fracture toughness value of the Mg<sub>2</sub>Al<sub>3</sub> layer is only 1.26&#xa0;MPa·m<sup>1/2</sup>.</p>

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Investigating Characteristics of CMT Directional Energy Deposition to Fabricate Al/Mg Multi-Material Structure

  • 期刊论文

  • 发表日期：

    2026年4月14日

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  • Xiaoming Nie,
  • Gaoyang Yu,
  • Rongzhi Huang,
  • Xueping Ding,
  • Baosheng Zhang,
  • Shuhai Chen

摘要

The key to heterogeneous structure additive manufacturing lies in the fusion of interfaces. In this paper, the forming characteristics, microstructures, and mechanical properties of Al/Mg dissimilar metals were investigated during wire-arc directed energy deposition based on the cold metal transfer (CMT) process. The results show that heat input affects the Al/Mg bimetallic structure’s geometry, porosity, and microstructures at the interface, with a specific emphasis on the intermetallic compounds (IMCs) formation, and the subsequent impact on the joint. The interface reaction zone is composed of Mg17Al12 + δ-Mg eutectic layer/ Mg17Al12 layer/ Mg2Al3 layer. Combined with thermodynamic calculations, the formation mechanism of compounds was clarified. The maximum compression–shear strength of the joints reached 48.45 MPa. Fracture analysis indicates that the crack propagates along the Mg2Al3 layer and eventually causes the joint to break. Experimental calculations also confirm that the fracture toughness value of the Mg2Al3 layer is only 1.26 MPa·m1/2.