In this study, additive manufacturing of a functionally graded material (FGM) as an alternative to joining dissimilar metals is investigated using directed energy deposition (DED). FGM consists of five different layers, which are mixtures of austenitic stainless steel (type 316 L) and low-alloy steel (LAS, ferritic steel) at ratios of 100:0 (A layer), 75:25 (B layer), 50:50 (C layer), 25:75 (D layer), and 0:100 (E layer), respectively, in each deposition layer. The FGM samples are successfully fabricated without cracks or delamination using the DED method, and specimens are characterized using optical and scanning electron microscopy to monitor their microstructures. In layers C and D of the sample, the tensile strength is determined to be very high owing to the formation of ferrite and martensite structures. However, the elongation is high in layers A and B, which contain a large fraction of austenite.

Processing of W-Cu graded materials from attritor-milled W-CuO mixtures is described. The powder reduction steps are investigated by TG and XRD analyses and by microstructural observations (SEM, TEM). Sintering of reduced powder with different compositions is analysed by dilatometry. Sintering behaviour of the graded component processed by co-compaction of a 10/20/30wt%Cu multi-layer material is briefly discussed. Liquid Cu migration is observed and smooths the composition gradient. Perspectives to control this migration are discussed.

Titanium cabide, TiC-x mole% Al composites, and functionally-graded materials (FGMs) of TiC-x mole% Al were synthesized by an electrothermal combustion (ETC) method. TiC-70 mole% Al composite was not ignited by indirect tungsten coil heating, but can be synthesized by an electrothermal combustion. The velocity of the combustion wave decreased with increasing addition of Al and increased with an increase in the applied electric field. Functionally-graded TiC-Al materials were made from reactant layers with compositions of Ti+C+x moles Al with x ranging from zero to 70 by an electrothermal combustion. In the FGM products a nearly linear change in composition in the graded region was observed in samples with 0 x 70 with x being the mole% Al.