Московский авиационный институт (национальный исследовательский университет), Москва, Россия

А. Д. Ежов, заведующий кафедрой авиационной и космической теплотехники, канд. техн. наук, эл. почта: ezzhov@gmail.com

В. П. Киселёв, старший преподаватель кафедры авиационной и космической теплотехники

ПАО «Ракетно-космическая корпорация «Энергия» им. С. П. Королёва», Королев, Россия
А. А. Басов, главный эксперт, канд. техн. наук, эл. почта: andrey.basov@rsce.ru
И. Е. Мальцев, генеральный директор, канд. техн. наук

Рассмотрены современные аддитивные технологии для изготовления биметаллических композиций, акцент сделан на их влияние на теплофизические свойства, в частности теплопроводность. Основное внимание уделено методам селективного лазерного сплавления (СЛС), прямого подвода энергии и материала (DED), включая электродуговую наплавку проволокой (WAAM), а также альтернативным подходам: электронно-лучевому сплавлению, холодному газодинамическому напылению и экструзии металлополимерных композитов. Подчеркнуто, что аддитивные процессы приводят к анизотропии микроструктуры и, как следствие, к направленной теплопроводности. Например, у сплава Cu – 2,4 Ni – 0,7 Si теплопроводность вдоль оси Z втрое выше, чем в поперечном направлении. Выполнен анализ ключевых проблем: образование трещин и пор на границе раздела фаз, термические напряжения, несовместимость коэффициентов термического расширения, а также усадка при охлаждении или спекании. Предложены решения: использование функционально-градиентных материалов (ФГМ), промежуточных слоев, оптимизация параметров энерговоздействия и стратегий подачи материалов. Представлено обсуждение методов контроля качества интерфейса и требований действующих стандартов (ГОСТ Р 59930–2021, NASA MSFC-STD-3716, ISO/ASTM TR 52905). В статье подчеркнута перспективность аддитивных биметаллов для теплообменных и токопроводящих элементов при условии комплексного управления структурой и свойствами границы раздела.

Работа выполнена в рамках гранта Министерства науки и высшего образования РФ №FSFF-2023-0006.

1. Griffis J. C., Shahed K., Meinert K., Yilmaz B., Lear M., Manogharan G. Multi-material laser powder bed fusion: effects of build orientation on defects, material structure and mechanical properties. npj Adv. Manuf 2025. Vol. 2, Iss. 1. 5.
2. Jarfors A. E. W. et al. On the nature of the anisotropy of Maraging steel (1.2709) in additive manufacturing through powder bed laser-based fusion processing. Materials & Design. 2021. Vol. 204. 109608.
3. Zhou Y. et al. Effect of crystallographic textures on thermal anisotropy of selective laser melted Cu – 2.4 Ni – 0.7Si alloy. Journal of Alloys and Compounds. 2018. Vol. 743. pp. 258–261.
4. Sukhov D. I. et al. Influence of the parameters of selective laser melting on the formation of porosity in the synthesized corrosion-resistant steel material. Trudy VIAM. 2017. No. 8. pp. 4.
5. Wu Z. et al. A review on experimentally observed mechanical and microstructural characteristics of interfaces in multi-material laser powder bed fusion. Front. Mech. Eng. 2023. Vol. 9. 1087021.
6. Chen K. et al. Selective laser melting 316L/CuSn10 multi-materials: Processing optimization, interfacial characterization and mechanical property. Journal of Materials Processing Technology. 2020. Vol. 283. 116701.
7. Sun Z. et al. Selective laser melting of stainless steel 316L with low porosity and high build rates. Materials & Design. 2016. Vol. 104. pp. 197–204.
8. Groden C. и др. Inconel 718-CoCrMo bimetallic structures through directed energy deposition-based additive manufacturing. MSAM. 2022. Vol. 1, Iss. 3. 18.

9. Squires L., Roberts E., Bandyopadhyay A. Radial bimetallic structures via wire arc directed energy deposition-based additive manufacturing. Nat. Commun. 2023. Vol. 14, Iss. 1. 3544.
10. Pragana J. P. M. et al. Hybrid metal additive manufacturing: A state–of–the-art review. Advances in Industrial and Manufacturing Engineering. 2021. Vol. 2. 100032.
11. Shah A. et al. A review of the recent developments and challenges in wire arc additive manufacturing (waam) process. JMMP. 2023. Vol. 7, Iss. 3. 97.
12. Wu B. et al. The effects of forced interpass cooling on the material properties of wire arc additively manufactured Ti6Al4V alloy. Journal of Materials Processing Technology. 2018. Vol. 258. pp. 97–105.
13. Wu B. et al. Effects of heat accumulation on microstructure and mechanical properties of Ti6Al4V alloy deposited by wire arc additive manufacturing. Additive Manufacturing. 2018. Vol. 23. pp. 151–160.
14. Belhadj M. et al. Effect of cold metal transfer-based wire arc additive manufacturing parameters on geometry and machining allowance. Int. J. Adv. Manuf. Technol. 2024. Vol. 131. pp. 739–748.
15. Li F. et al. Thermoelectric cooling-aided bead geometry regulation in wire and arc-based additive manufacturing of thin-walled structures. Applied Sciences. 2018. Vol. 8, Iss. 2. 207.
16. Afrouzian A. et al. Additive manufacturing of Ti – Ni bimetallic structures. Materials & Design. 2022. Vol. 215. 110461.
17. Bandyopadhyay A., Zhang Y., Onuike B. Additive manufacturing of bimetallic structures. Virtual and Physical Prototyping. 2022. Vol. 17, Iss. 2. pp. 256–294.
18. Hussain M. S., Mardi K. B., Mandal A. Fabrication of FGM structure with gradation of stainless steel and low carbon steel using twin wire arc additive manufacturing. Weld World. 2025. Vol. 69, Iss. 11. pp. 3467–3481.
19. Ahsan Md. R. U. et al. Fabrication of bimetallic additively manufactured structure (BAMS) of low carbon steel and 316L austenitic stainless steel with wire + arc additive manufacturing. RPJ. 2019. Vol. 26, Iss. 3. pp. 519–530.
20. Chumaevsky A.V. et al. Formation of inhomogeneities and defects in the structure of composite materials and functionally gradient bimetallic products obtained by the method of wire electron beam additive technology. Vestnik SibGIU. 2023. Vol. 1, No. 1. pp. 66–75.
21. Lehmann T. et al. Concurrent geometry- and material-based process identification and optimization for robotic CMT-based wire arc additive manufacturing. Materials & Design. 2020. Vol. 194. 108841.
22. Suryakumar S. et al. Weld bead modeling and process optimization in Hybrid Layered Manufacturing. Computer-Aided Design. 2011. Vol. 43, Iss. 4. pp. 331–344.
23. Ding D. et al. A multi-bead overlapping model for robotic wire and arc additive manufacturing (WAAM). Robotics and Computer-Integrated Manufacturing. 2015. Vol. 31. pp. 101–110.
24. Bera T., Mohanty S. A review on residual stress in metal additive manufacturing. 3D printing and additive manufacturing. 2024. Vol. 11, Iss. 4. pp. 1462– 1470.
25. Li R. et al. Simulation of residual stress and distortion evolution in dualrobot collaborative wire-arc additive manufactured Al – Cu alloys. Virtual and Physical Prototyping. 2024. Vol. 19, Iss. 1. e2409390.
26. GOST R 59930–2021 ISO/АSTM 52904:2019. Additive technologies. Powder bed fusion process to meet critical applications. General provisions.
27. Nikitin P. V. Heterogeneous flows in innovation technologies. Moscow : Yanus-К, 2010. 244 p.
28.Vaz R. et al. A review of advances in cold spray additive manufacturing. Coatings. 2023. Vol. 13, Iss. 2. 267.
29.Wu H. et al. Bonding behavior of Bi-metal-deposits produced by hybrid cold spray additive manufacturing. Journal of Materials Processing Technology. 2022. Vol. 299. 117375.
30. Mazeeva A. et al. Multi-metal additive manufacturing by extrusion-based 3D printing for structural applications: a review. Metals. 2024. Vol. 14, Iss. 11. 1296.
31. Ferro P. et al. Creating IN718-high carbon steel bi-metallic parts by fused deposition modeling and sintering. Procedia Structural Integrity. 2023. Vol. 47. pp. 535–544.
32. Ferro P. et al. High carbon steel/Inconel 718 bimetallic parts produced via fused filament fabrication and sintering. Frattura ed Integrità Strutturale. 2023. Vol. 17, Iss. 65. pp. 246–256.
33. Laleh M. и др. Heat treatment for metal additive manufacturing. Progress in Materials Science. 2023. Vol. 133. 101051.
34. Zhang L. et al. Additive manufacturing of Inconel 718/CuCrZr multi–metallic materials fabricated by laser powder bed fusion. Additive Manufacturing. 2024. Vol. 92. 104377.
35. Ghanavati R. et al. Residual stresses and distortion in additively-manufactured SS316L-IN718 multi-material by laser-directed energy deposition: A validated numerical-statistical approach. Journal of Manufacturing Processes. 2023. Vol. 108. pp. 292–309.
36. Anand C. et al. A review on additive production of functionally graded materials based on titanium. Proceedings of the International Conference on Advancements in Materials, Design and Manufacturing for Sustainable Development, ICAMDMS 2024. 23–24 February 2024, Coimbatore, Tamil Nadu, India. Coimbatore, India: EAI, 2024. DOI: 10.4108/eai.23-2-2024.2346987
37. Chen N. et al. Microstructural characteristics and crack formation in additively manufactured bimetal material of 316L stainless steel and Inconel 625. Additive Manufacturing. 2020. Vol. 32. 101037.
38. Kim E. S. et al. Local composition detouring for defect-free compositionally graded materials in additive manufacturing. Materials Research Letters. 2023. Vol. 11, Iss. 7. pp. 586–594.
39. Mousapour M. et al. Feasibility study of producing multi-metal parts by fused filament fabrication (FFF) technique. Journal of Manufacturing Processes. 2021. Vol. 67. pp. 438–446.
40. Kim T., Kim S. Hot-end co-extrusion of multiple thermoplastic filaments for unblended composite additive manufacturing. Virtual and Physical Prototyping. 2025. Vol. 20, Iss. 1. 2526797.
41. N. Samad S. et al. Multi-material additive manufacturing of metals: A review of structures and mechanical characteristics. ESAM. 2025. Vol. 1, Iss. 2. 025180010.
42. MSFC-STD-3716. Standard for additively manufactured spaceflight hardware by laser powder bed fusion in metals.
43. Russell R. NASA’s efforts for the development of standards for additive manufactured components. Structural Integrity of Additive Manufactured Parts. ASTM International 100 Barr Harbor Drive, PO Box C700. West Conshohocken, PA 19428-2959, 2020. pp. 573–581.
44. ISO/ASTM TR 52905:2023. Additive manufacturing of metals. Non-destructive testing and evaluation. Defect detection in parts.
45. Basov А. А., Кorobov К. S., Lesnevsky L. N., Nikolaev I. А., Ripetsky А. V. Analysis of the roughness of the AlSi10Mg alloy obtained by selective laser melting for use in spacecraft heat exchange elements. Teplovye protsessy v tekhnike. 2025. No. 3. pp. 111–122.
46. Aslanyan I. R., Eremkina M. S., Zamyshlyaev D. A., Maltsev I. E. Development of a method for cleaning the surface of parts obtained by additive methods. Elektrometallurgiya. 2022. No. 12. pp. 30–36.