Solid-State Dissimilar Bulk Joining of Additively Manufactured Maraging Steel and Conventional Martensitic Stainless Steel

Solid-state dissimilar bulk joining of additively manufactured maraging steel and commercially available martensitic stainless steel (AISI410) is accomplished through electrically assisted pressure joining (EAPJ). The additively manufactured cylindrical maraging steel specimen is fabricated to have a porous layer on the joining end, while another end is printed as a perfectly solid matrix. The porous layer significantly increases the maximum joining temperature by the locally increased electrical resistance and dramatically enhances the interfacial diffusion thickness. The effect of the porous layer on the microstructural evolution and mechanical properties is characterized by the EBSD and quasi-static tensile test, respectively. 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.