Table 2 The summary of the added...

Table 2

The summary of the added functionalities and materials with potential application areas, challenges and possible solutions

Required functionality	Added material in the pair	Reported pairs	Potential application	Challenges	Possible solution	Ref
Strength and ductility	Stainless steel to copper alloys	316L to Cu10Sn	Heat exchangers, electrical components, cryogenic, heat sinks in fusion reactors and rocket engines	Brittle intermetallic formation, high melting point, thermal expansion, and thermal conductivity mismatches, LME cracking	Highly optimized process parameters to mitigate thermal differences, Ni addition as an interlayer or as an element at the interface to mitigate intermetallic formation if needed.	(Wei et al., 2019; Chen et al., 2022)
	Nickel alloys to copper alloys	In718 to GRCop42	Rocket engine combustion chambers and fusion reactors with high-temperature strength requirements	Low intermetallic formation risk, but high melting point and thermal conductivity mismatch, therefore, lack of fusion and residual stresses	Optimized process parameter designs	(Wei et al., 2021)
		In718 to Pure copper
		Invar36 to Cu10Sn
	Nickel alloys to stainless steel	In718 to 316 L	Exhaust components, pressure vessels, steam and gas turbine blades, molds, aircraft landing gear, nuclear reactor components for localized high temperature strength	Good thermal matching properties, and good solubility, but brittle intermetallic formation, carbide precipitation	Optimizing process parameters to reduce the formation of brittle intermetallic phases and carbides by nonequilibrium solidification simulations such as Scheil-Gulliver	(Wei et al., 2018; Duval-Chaneac et al., 2021; Mohd Yusuf et al., 2021; Wits and Amsterdam, 2021)
	Nickel alloys to stainless steel	HastelloyX to 316 L
	Martensitic stainless steel to austenitic stainless steel	MS1 to 316 L	Power generation parts such as ultra-supercritical power plants (USC),	Thermal expansion mismatch	Optimized process parameters, or gradient to mitigate the thermal expansion mismatch	(Nadimpalli et al., 2019; Liang et al., 2023)
	Martensitic stainless steel to austenitic stainless steel	15-5PH to 316 L		Thermal expansion mismatch		(Nadimpalli et al., 2019; Liang et al., 2023)
	Cobalt alloys to stainless steel	CoCrMo to MS1	Tooling and mold making such as dies and cutting tools, for high-temperature resistance and superior toughness	Matching thermal properties and low chance of intermetallic, but less dynamic melt Pool and intermixing, solute segregation	Optimized process parameters followed by a post heat treatment	(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to stainless steel	CoCrMo to 17-4PH				(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to titanium alloys	CoCrMo to Ti6Al4V	Medical applications for superior local strength	Formation of some brittle phases (although rapid solidification in LPBF mitigates most), thermal expansion mismatch,	Optimized process parameters, gradient interface to solve the thermal expansion mismatch problem	(Bartolomeu et al., 2023)
	Titanium alloys to aluminum alloys	Ti6Al4V to AlSi10Mg	Increasing local strength in lightweight components in aerospace	Very brittle intermetallic formation, melting point and thermal expansion mismatch,	Introducing a compatible interlayer such as copper at the interface	(Sing et al., 2015; Wu et al., 2022; Zhang et al., 2023),
Wear resistance	Martensitic stainless steel to austenitic stainless steel	MS1 to 316 L	Coating and surface protection in energy section parts	Thermal expansion mismatch, some lack of fusion	Optimized process parameters	(Nadimpalli et al., 2019; Liang et al., 2023)
		15-5PH to 316 L
		MS300 to SS420
	Cobalt alloys to stainless steel	Co37Cr7Mo to MS1	Coating and surface protection in tooling	Good bonding due to matching properties	Heat treatment for precipitation strengthening and stress relief	(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to stainless steel	17-4PH to CoCrMo	Coating and surface protection in tooling	Good bonding due to matching properties		(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to titanium alloys	CoCrMo to Ti6Al4V	Superior wear resistance for titanium bone implants, knee replacements, and hip joints	Thermal expansion mismatch	Gradient interfaces	(Bartolomeu et al., 2023)
Corrosion resistance	Pure titanium to titanium alloys	Pure Ti to Ti6Al4V	Medical implants to reduce releasing toxic vanadium impurities	Brittle intermetallic phases despite belonging to the same alloying systems	Possibly intermetallic phases, or optimized process parameters to bypass the brittle intermetallic phase regions	(Zhang et al., 2018; Borisov et al., 2021)
	Nickel alloys to stainless steel	Inconel HX to 316 L	Highly reactive salt reactors for high temperature corrosion resistance	Matching thermophysical properties, but some carbides and intermetallics formation risk	Optimizing process parameters	(Duval-Chaneac et al., 2021; Rankouhi et al., 2022)
	Nickel alloys to stainless steel	In718 to 316 L			Optimizing process parameters	(Duval-Chaneac et al., 2021; Rankouhi et al., 2022)
Electrical and thermal conductivity	Copper alloys to stainless steel and tool steel	Pure Cu to H13	Copper cooling channels in manufacturing tools such as dies and molds	High copper reflectivity and poor Fe-Cu solubility, thermal properties mismatch,	Optimized process parameters and using gradients	(Fu, Yeong and Chen, 2016; Schneck et al., 2021; Cunha et al., 2022)
		Cu10Sn to 316 L
		Copper 2.1293 to steel 1.2709
		Pure Cu to SS420
	Copper alloys to nickel alloys	Pure Cu to In718	Local electrical and thermal conductivies in aerospace components	Mismatch in thermal properties	Optimized process parameters and using gradients	(Wei et al., 2021; Marques et al., 2022)
	Copper alloys to titanium alloys	Cu10Sn to Ti6Al4V	Local electrical and thermal conductivies in aerospace components	Melting temperature and thermal expansion mismatch	Gradients with optimized process parameters	(Wei et al., 2022)
	Silver to copper alloys	Ag7.5Cu to Cu10Sn	High temperature conductivity applications (HETCs)	Unstable keyhole	Placing Cu10Sn on top and higher thermal conductive material (silver) at the bottom	(Chen et al., 2023)
Shape memory and superelasticity	Nickel-titanium to titanium alloys	NiTi to 316 L	Bearing and gears for extrinsic (Two-way effect), local shape memory effect in minimally invasive surgery and diagnostic tools such as stents, filters, etc.	Highly dependent on the optimizing process parameters to have customized process parameters, brittle intermetallic phases, thermal properties mismatches	Optimizing process parameters, gradients	(Ekoi et al., 2022)

Required functionality	Added material in the pair	Reported pairs	Potential application	Challenges	Possible solution	Ref
Strength and ductility	Stainless steel to copper alloys	316L to Cu10Sn	Heat exchangers, electrical components, cryogenic, heat sinks in fusion reactors and rocket engines	Brittle intermetallic formation, high melting point, thermal expansion, and thermal conductivity mismatches, LME cracking	Highly optimized process parameters to mitigate thermal differences, Ni addition as an interlayer or as an element at the interface to mitigate intermetallic formation if needed.	(Wei et al., 2019; Chen et al., 2022)
	Nickel alloys to copper alloys	In718 to GRCop42	Rocket engine combustion chambers and fusion reactors with high-temperature strength requirements	Low intermetallic formation risk, but high melting point and thermal conductivity mismatch, therefore, lack of fusion and residual stresses	Optimized process parameter designs	(Wei et al., 2021)
		In718 to Pure copper
		Invar36 to Cu10Sn
	Nickel alloys to stainless steel	In718 to 316 L	Exhaust components, pressure vessels, steam and gas turbine blades, molds, aircraft landing gear, nuclear reactor components for localized high temperature strength	Good thermal matching properties, and good solubility, but brittle intermetallic formation, carbide precipitation	Optimizing process parameters to reduce the formation of brittle intermetallic phases and carbides by nonequilibrium solidification simulations such as Scheil-Gulliver	(Wei et al., 2018; Duval-Chaneac et al., 2021; Mohd Yusuf et al., 2021; Wits and Amsterdam, 2021)
	Nickel alloys to stainless steel	HastelloyX to 316 L
	Martensitic stainless steel to austenitic stainless steel	MS1 to 316 L	Power generation parts such as ultra-supercritical power plants (USC),	Thermal expansion mismatch	Optimized process parameters, or gradient to mitigate the thermal expansion mismatch	(Nadimpalli et al., 2019; Liang et al., 2023)
	Martensitic stainless steel to austenitic stainless steel	15-5PH to 316 L		Thermal expansion mismatch		(Nadimpalli et al., 2019; Liang et al., 2023)
	Cobalt alloys to stainless steel	CoCrMo to MS1	Tooling and mold making such as dies and cutting tools, for high-temperature resistance and superior toughness	Matching thermal properties and low chance of intermetallic, but less dynamic melt Pool and intermixing, solute segregation	Optimized process parameters followed by a post heat treatment	(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to stainless steel	CoCrMo to 17-4PH				(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to titanium alloys	CoCrMo to Ti6Al4V	Medical applications for superior local strength	Formation of some brittle phases (although rapid solidification in LPBF mitigates most), thermal expansion mismatch,	Optimized process parameters, gradient interface to solve the thermal expansion mismatch problem	(Bartolomeu et al., 2023)
	Titanium alloys to aluminum alloys	Ti6Al4V to AlSi10Mg	Increasing local strength in lightweight components in aerospace	Very brittle intermetallic formation, melting point and thermal expansion mismatch,	Introducing a compatible interlayer such as copper at the interface	(Sing et al., 2015; Wu et al., 2022; Zhang et al., 2023),
Wear resistance	Martensitic stainless steel to austenitic stainless steel	MS1 to 316 L	Coating and surface protection in energy section parts	Thermal expansion mismatch, some lack of fusion	Optimized process parameters	(Nadimpalli et al., 2019; Liang et al., 2023)
		15-5PH to 316 L
		MS300 to SS420
	Cobalt alloys to stainless steel	Co37Cr7Mo to MS1	Coating and surface protection in tooling	Good bonding due to matching properties	Heat treatment for precipitation strengthening and stress relief	(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to stainless steel	17-4PH to CoCrMo	Coating and surface protection in tooling	Good bonding due to matching properties		(Steponavičiūtė et al., 2022; Pasco et al., 2023)
	Cobalt alloys to titanium alloys	CoCrMo to Ti6Al4V	Superior wear resistance for titanium bone implants, knee replacements, and hip joints	Thermal expansion mismatch	Gradient interfaces	(Bartolomeu et al., 2023)
Corrosion resistance	Pure titanium to titanium alloys	Pure Ti to Ti6Al4V	Medical implants to reduce releasing toxic vanadium impurities	Brittle intermetallic phases despite belonging to the same alloying systems	Possibly intermetallic phases, or optimized process parameters to bypass the brittle intermetallic phase regions	(Zhang et al., 2018; Borisov et al., 2021)
	Nickel alloys to stainless steel	Inconel HX to 316 L	Highly reactive salt reactors for high temperature corrosion resistance	Matching thermophysical properties, but some carbides and intermetallics formation risk	Optimizing process parameters	(Duval-Chaneac et al., 2021; Rankouhi et al., 2022)
	Nickel alloys to stainless steel	In718 to 316 L			Optimizing process parameters	(Duval-Chaneac et al., 2021; Rankouhi et al., 2022)
Electrical and thermal conductivity	Copper alloys to stainless steel and tool steel	Pure Cu to H13	Copper cooling channels in manufacturing tools such as dies and molds	High copper reflectivity and poor Fe-Cu solubility, thermal properties mismatch,	Optimized process parameters and using gradients	(Fu, Yeong and Chen, 2016; Schneck et al., 2021; Cunha et al., 2022)
		Cu10Sn to 316 L
		Copper 2.1293 to steel 1.2709
		Pure Cu to SS420
	Copper alloys to nickel alloys	Pure Cu to In718	Local electrical and thermal conductivies in aerospace components	Mismatch in thermal properties	Optimized process parameters and using gradients	(Wei et al., 2021; Marques et al., 2022)
	Copper alloys to titanium alloys	Cu10Sn to Ti6Al4V	Local electrical and thermal conductivies in aerospace components	Melting temperature and thermal expansion mismatch	Gradients with optimized process parameters	(Wei et al., 2022)
	Silver to copper alloys	Ag7.5Cu to Cu10Sn	High temperature conductivity applications (HETCs)	Unstable keyhole	Placing Cu10Sn on top and higher thermal conductive material (silver) at the bottom	(Chen et al., 2023)
Shape memory and superelasticity	Nickel-titanium to titanium alloys	NiTi to 316 L	Bearing and gears for extrinsic (Two-way effect), local shape memory effect in minimally invasive surgery and diagnostic tools such as stents, filters, etc.	Highly dependent on the optimizing process parameters to have customized process parameters, brittle intermetallic phases, thermal properties mismatches	Optimizing process parameters, gradients	(Ekoi et al., 2022)

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