A Systematic Study on Layer-Level Multi-Material Fabrication of Parts via Laser-Powder Bed Fusion Process

In this work, a systematic study was conducted on the fabrication of multi-material components obtained employing Laser-Powder Bed Fusion (L-PBF) technology. The idea of making multi-material components is a winning capability of additive technologies because it allows for the fabrication of Functionally Graded Materials (FGMs) with the customization of parts according to different required properties. This study aims to determine the ability of an inexpensive system, adaptable to the L-PBF machines already on the market, with a powder-spreading technique based on coaters or rollers, to produce parts with continuously variable properties in each layer. Also, the correlation between certain selectable factors in the production design and the result obtained in terms of metallurgical and mechanical properties and chemical composition was investigated. The factors studied were the relative position of the different materials within the powder chamber and the geometry of the equipment designed to produce the cFGMs components. The performed tests involved the use of two materials, a nickel-based superalloy, and a stainless steel, having different chemical, physical, and mechanical properties to obtain gradual property variations in the manufactured samples. Based on the results of post-process characterization obtained via metallographic, chemical, and mechanical analysis, the relative positions of the materials and the geometry of the developed equipment have a limited effect on the sample's manufactured properties. The characteristics of the FGM zone depend on the nature of the employed powders, and its extent coincides with that defined during the design of the divider.