Additive Manufacturing of a Steel–Ceramic Multi-Material by Selective Laser Melting

Most techniques employed for powder bed additive manufacturing (AM) only can handle a single material. However, additional functionality of the structures built, e.g., local insulation, is desirable for more sophisticated applications. In the present work, a multi-material process allowing for realization of a ceramic coating on a steel substrate and a novel sandwich system are introduced. Both were manufactured by selective laser melting (SLM). As a first step, the microstructure of a bulk zirconia–alumina ceramic, directly manufactured by SLM, was examined and its tensile strength determined. Afterwards, the ceramic was manufactured directly on the as-built surface of a tool steel processed by SLM. For this compound, the adhesive strength was determined. Finally, an open porous structure, made of the same tool steel, was built on top of the ceramic layer. The results clearly prove that the SLM process can be used for direct manufacturing of a multi-material sandwich structure made from metal and ceramic, providing an important step towards complex structures functionalized for electric insulation.