Design and fabrication of Al-Mg bimetallic interface structures via synergistic additive manufacturing and powder hot pressing

The Al-Mg bimetallic structure combines the advantages of both Al and Mg alloys and has attracted significant attention in the design of lightweight components. However, enhancing the bonding strength at the alloy interface remains a critical challenge. In this study, four types of Al-Mg alloy interface structures are designed and fabricated by integrating metallurgical bonding with mechanical interlocking, and their interfacial bonding characteristics are investigated and analyzed. The results indicate that Al-Mg alloy interfaces with lattice structures exhibit better bonding effect compared to the elliptical and anti-trapezoidal suture structures, especially in the case of the gradient BCC lattice structure. The interface with gradient lattice structure exhibits no significant defects, an enlarged element diffusion zone, and a more uniform elemental distribution, all of which contribute to enhanced bonding performance. This study provides effective design strategies and technical support to promote the development of bimetallic interfaces.