On the role of interface strategy in multi-scale hybrid additive manufacturing

On the role of interface strategy in multi-scale hybrid additive manufacturing | 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 Article On the role of interface strategy in multi-scale hybrid additive manufacturing Alan Burl, Zaky Hussien, Venkata Surya Karthik Adapa, Melissa Foley, and 5 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6198428/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 11 You are reading this latest preprint version Abstract As multiple macro scale directed energy deposition (DED) processes begin to be industrially adopted for large scale component manufacture, it is imperative that interface strategies between the processes are fully understood. The present work investigates the asynchronous deposition of a wire component (DED-arc), followed by a powder-based deposition (DED-LP) with varying surface treatments which were evaluated for flatness, porosity, hardness, and Charpy impact energy. The self-regulation effect of DED-LP was fully realized with up to \SI{55}{\percent} reduction in surface variation relative to the DED-arc surface. Contrarily, as surface contaminants were not removed between each process, the resultant DED-LP porosity was significantly reduced from \SI{99.5}{\percent} to \SI{92.4}{\percent}. Albeit the reduction in density did not negatively impact the impact toughness as evidenced by a low correlation coefficient of -0.46. As such, the overall manufacturing costs and application space must be considered for selection of the different interface strategies presented in the current work. Physical sciences/Engineering/Mechanical engineering Physical sciences/Materials science/Structural materials/Metals and alloys Hybrid Manufacturing Directed Energy Deposition Wire-Arc Additive Manufacturing Additive Manufacturing Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Under Review Version 1 posted Editorial decision: Revision requested 20 Apr, 2025 Reviews received at journal 17 Apr, 2025 Reviews received at journal 17 Apr, 2025 Reviews received at journal 30 Mar, 2025 Reviewers agreed at journal 26 Mar, 2025 Reviewers agreed at journal 25 Mar, 2025 Reviewers agreed at journal 22 Mar, 2025 Reviewers invited by journal 21 Mar, 2025 Editor assigned by journal 13 Mar, 2025 Submission checks completed at journal 13 Mar, 2025 First submitted to journal 10 Mar, 2025 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-6198428","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":428619029,"identity":"559c02ef-79d9-4806-8f10-df2ae1c61509","order_by":0,"name":"Alan 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