A review on additive manufacturing of dissimilar metals: current challenges, industrial applications, and AI/ML integration strategies

Additive manufacturing (AM) possesses the capacity to transform production and materials engineering by facilitating the amalgamation of dissimilar metals to create components that are lightweight, durable, and economical. This study provides a thorough analysis of the status of AM for dissimilar materials, including advantages, limitations, and diverse industrial applications. Identified key problems encompass material incompatibility, thermal stress impacts, and the development of brittle intermetallic compounds. A variety of strategies for material integration in AM are examined, including insights into material classifications, mechanical properties, industrial uses, and persistent problems. The incorporation of artificial intelligence (AI) and machine learning (ML) in augmenting the functionalities of AM is examined. This integration seeks to enhance industrial applications, forecast material behaviours, and promote the creation of innovative material combinations while addressing existing obstacles related to AI and ML integration. This paper provides a comprehensive examination of the opportunities and problems associated with the AM of heterogeneous materials, acting as a reference for future research and development initiatives to maximize the potential of this disruptive technology.