Effectiveness of an additively manufactured porous layer in dissimilar solid-state bulk joining of additively manufactured maraging steel and conventional AISI410 steel

Abstract

Solid-state bulk joining of additively manufactured maraging steel and commercially available martensitic stainless steel (AISI410) specimens in a cylindrical shape is accomplished through electrically assisted pressure joining (EAPJ). The cylindrical maraging steel specimen is fabricated to have a porous layer on the joining side by selective laser melting additive manufacturing. During EAPJ, the porous layer, which serves as an interlayer with locally increased electrical resistance due to geometrically induced defects (pores), significantly and locally increases the maximum temperature while the joining load is dramatically decreased. The microstructure evolution suggests that grain refinement occurs on both the maraging steel and AISI410 sides due to recrystallization. The high residual stress induced during additive manufacturing of maraging steel specimens is significantly released during EAPJ. Martensite formation in the AISI410 steel and the reverted austenite in the maraging steel are characterized by the grain average image quality. Tensile tests show that the fracture always occurs in the transition region between the heat-affected region and the unaffected base metal region. The present study demonstrates that bulk joining of additively manufactured components and conventional components can be more easily and effectively achieved with the use of an additively manufactured porous layer, even for dissimilar material combinations.