Fabrication of SS304/Cu/Al Layered Gradient Composites by WAAM: Interfacial Behavior and Mechanical Properties

HUANG Qiang; LIU Qingwei; ZHENG Xudong; LU Shuping; SU Lei; LIANG Biqiang; ZHOU Keqiu

doi:10.3969/j.issn.1674-6457.2026.10.006

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (10) : 56-64. DOI: 10.3969/j.issn.1674-6457.2026.10.006

Composites Forming

Fabrication of SS304/Cu/Al Layered Gradient Composites by WAAM: Interfacial Behavior and Mechanical Properties

HUANG Qiang^1,*, LIU Qingwei¹, ZHENG Xudong¹, LU Shuping¹, SU Lei¹, LIANG Biqiang¹, ZHOU Keqiu²

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Abstract

The work aims to fabricate SS304/Cu/Al layered composites through the WAAM process to investigate their microstructure and macroscopic mechanical properties, and provide a new approach for the preparation of aluminum-stainless steel materials. A Cu substrate was prepared as a transitional bonding layer. Combining the high heat input and flexible forming advantages of the WAAM process, interfacial products were effectively controlled while promoting good interfacial bonding. SEM, EDS, XRD, and tensile testing were used to analyze the macroscopic mechanical properties and microstructure of the layered composites. Interfacial microstructure and phase analysis showed that the Cu substrate, as a transitional layer, effectively suppressed the formation of brittle phases at the interface, resulting in a distinct wavy interfacial morphology. The elemental diffusion layer thicknesses at the SS304-Cu substrate interface and the Al-Cu substrate interface were 2 μm and 53 μm, respectively. Bending, tensile tests, and fracture morphology revealed a clear stepwise decrease in stress-strain curves. Optimized heat input parameters lead to favorable kinetic characteristics between the heterogeneous materials, promoting interfacial bonding. Multi-level failure modes and excellent crack propagation resistance enable the layered composites to exhibit superior structural safety and damage tolerance.

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SS304/Cu/Al / layered gradient composites / WAAM / interfacial behavior / mechanical properties

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HUANG Qiang, LIU Qingwei, ZHENG Xudong, LU Shuping, SU Lei, LIANG Biqiang, ZHOU Keqiu. Fabrication of SS304/Cu/Al Layered Gradient Composites by WAAM: Interfacial Behavior and Mechanical Properties[J]. Journal of Netshape Forming Engineering. 2026, 18(10): 56-64 https://doi.org/10.3969/j.issn.1674-6457.2026.10.006

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