Ultrahigh Bonding Strength of Dissimilar Metals Manufactured through Additive Manufacturing

Abstract Dissimilar metals have exceptional development prospects in many fields due to their unique properties. However, the formation of brittle intermetallic compounds (IMCs) in dissimilar metals significantly reduces the bonding strength and causes interface cracking. In this study, a novel solid solution design concept is proposed to solve the problem. And ultrahigh bonding strength of TC4 titanium alloy/316L stainless steel dissimilar metal is achieved through additive manufacturing, with a CrCuV solid solution alloy interlayer. By utilizing the high‐entropy effect, continuous solid solutions are formed and the brittle IMCs layer is completely inhibited at the heterogeneous interface. The excellent metallurgical bonding of TC4/316L dissimilar metal results in an unprecedented shear strength of 345 MPa. This strategy successfully breaks through the bottleneck of bonding strength in dissimilar metals, greatly promotes the development and application of dissimilar metals.