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The additive manufacturing (AM) of bi-metal structure has received much interest because it provides compensated properties for a single metal alloy, meeting the harsh requirements for components used in key industries like aerospace, defense, energy, etc. However, fusion-based AM technologies usually induce interfacial cracks and delamination resulted from the large mismatch of coefficient of thermal expansion (CTE) between dissimilar materials, while the solid-state AM methods generate a large number of pores at the interface, requiring post-fabrication heat treatment. In this study, we aim to build high-quality 17-4 PH stainless steel and nickel alloy bi-metal structure with material extrusion AM method, followed by debinding and sintering processes. The microstructure and mechanical properties of the bi-metal structure were thoroughly investigated. The completion of this study provides a pioneering analysis of bi-metal structures built by extrusion-based sintering-assisted AM and shows a great promise for further adoption in a variety of industrial applications.



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Bi-metal Structures Fabricated by Extrusion-based Sintering-assisted Additive Manufacturing