Analysis of the Bimetallic Joint of a Hot-Forged Crosshead Composed of ASTM B221 6060 Aluminum and AWS A5.36 E110C-G M Low Alloy Steel Obtained by Localized Fusion Additive Manufacturing

In this study, the development of a bimetallic crosshead produced by additive manufacturing (AM) is discussed, evaluating the joint region between the two metals. The focus was on investigating the metallurgical aspect of this hybrid part, particularly the effect of warm forging at the interface, which combines attributes of two different metal alloys. Fabrication of the crossheads involved metal deposition, resulting in a wear-resistant outer layer using AWS A5.36 E110C-G M welding wire and an inner layer filled with ASTM B221 6060 rolled aluminum. The analyses showed that the intermetallic region had good adhesion properties after warm forging, although excessive formation of iron oxides could compromise the ductility of the joint. The results indicate that, with the formation of intermetallic phases minimized, additive manufacturing makes it possible to create complex high-performance components with customized properties, serving as a guide for evaluating the viability of this approach in further studies.