Abstract: For searching alternative strategies to improve reliability of titanium and steel dissimilar bimetallic joints manufactured by directed energy deposition with laser beam (DED-LB), pure titanium was considered as cladding deposited on carbon steel substrate with Ni-based alloy interlayers in this work. Effect of different interlayer modification methods on the microstructure evolution and mechanical properties of joints was analyzed systematically. The distribution of intermetallic compounds (IMCs) such as β-Ti, Ti₂Ni, TiNiFe_0.2, Ti₂Ni₃Si and TiB₂ in joints was revealed. The results showed that original deposition cracks caused by residual stress during processing could be alleviated by substrate preheating treatment while suppressed by the modified interlayer with Cr completely. Notably, additional Cr could reduce reaction activity between Ti and Ni atoms by raising laser molten pool liquidus, leading to fewer IMCs in joints. As a result, both bonding strength and toughness of joints were remarkably improved. The findings emphasize more significance of optimizing Ni-based interlayer composition with Cr than preheating method to improve the mechanical performance of DED-LB joints.

Key words: Dissimilar joints, Directed energy deposition (DED), Intermetallic compounds, Shear strength, Ni-based interlayer