Improvement of buildability and joint strength in wire-arc DED of pure titanium onto magnesium alloy via mechanical interlocking strategy

Improvement of buildability and joint strength in wire-arc DED of pure titanium onto magnesium alloy via mechanical interlocking strategy | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Improvement of buildability and joint strength in wire-arc DED of pure titanium onto magnesium alloy via mechanical interlocking strategy Yuto Ohta, Hisaya Komen, Hiroyuki Sasahara, Hideaki Nagamatsu This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9357477/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 3 You are reading this latest preprint version Abstract Depositing pure titanium (Ti) onto magnesium (Mg) alloy via wire-arc directed energy deposition can produce high-performance components with superior specific strength. However, the formation of brittle intermetallic compounds and the instability of droplet transfer and arc plasma induced by Mg vapor significantly degrade both bondability and buildability. Although a mechanical interlocking strategy involving alternating two materials deposition could overcome these issues, previous studies have primarily focused on the mechanical performance of interlocked structures. The interplay between arc plasma stability, molten metal behavior, and the resulting structural integrity remains systematically unaddressed. Therefore, this study aims to clarify the physical factors hindering sound bead formation in ERTi-2-on-AZ31 and to demonstrate the effectiveness of a mechanical interlocking strategy. In the conventional strategy, ERTi-2-on-AZ31 deposition exhibited short-circuit or globular transfer, whereas one-drop-per-pulse transfer was achieved in ERTi-2-on-ERTi-2 under same conditions. This difference is attributed to a reduced electromagnetic pinch force and increased pressure beneath the molten wire, caused by Mg vapor evaporated from the AZ31 molten pool flowing upward against the Ti-rich plasma flow. Furthermore, higher arc currents generated excessive Mg vapor, causing molten ERTi-2 to scatter as spatter and preventing bead formation. In contrast, the mechanical interlocking strategy enabled the fabrication of ERTi-2-on-AZ31 components with internal ERTi-2 strut by maintaining arc discharge between similar metals. Sufficient penetration between similar metals ensured highly reproducible tensile results, with the maximum strength of 80 MPa. Increasing the interlayer waviness of the struts shifted the failure mode from strut fracture to strut pull-out. Multi-material additive manufacturing Wire arc directed energy deposition Molten metal droplet transfer Arc plasma Mechanical interlocking Tensile properties Full Text Supplementary Files 1TiTi100AMono.mp4 2TiTi100AColor.mp4 3TiMg100AMono.mp4 4TiMg100AColor.mp4 5TiMg66AStart.mp4 6TiMg66Arebuild.mp4 Cite Share Download PDF Status: Under Review Version 1 posted Reviewers invited by journal 13 Apr, 2026 Editor assigned by journal 09 Apr, 2026 First submitted to journal 08 Apr, 2026 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9357477","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":622542409,"identity":"003f64b5-6c81-4af9-be54-2ac87cc097d4","order_by":0,"name":"Yuto Ohta","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yuto","middleName":"","lastName":"Ohta","suffix":""},{"id":622542410,"identity":"bd89566c-f2d9-4a59-94ee-d84ca19389ad","order_by":1,"name":"Hisaya 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