Abstract: The traditional steel/lead bonding structures are based on bonding process, which can lead to serious problems in the application and long-term storage, such as local strap debonding, aging and strength degradation. The above-mentioned problems seriously affect the integrity, long-term stability and environmental adaptability of steel/lead composite structures. This paper puts forward a novel additive manufacturing me-thod to fabricate 45 steel/lead alloy bimetallic structures by direct metallurgical connection, which is a combination of droplet deposition manufacturing and variable-polarity TIG arc process. The microstructure and mechanical properties of the fabricated samples were analyzed by using many experimental means such as OM, SEM, EDS, microhardness test, and so on. The results showed that a nonlinear relationship existed between the heat input of the welding arc and the feature sizes (deposition height and width) of the lead alloy deposited layers. No evidence of cracks and micro voids was found at the bonding interface. The thickness of the interfacial reaction layer is within the range of 30—70 μm. The average interfacial bonding strength of the fabricated sample can reach 28.4 MPa, which is much higher than 4.2 MPa of the report. The fracture location is always on the side of lead alloy deposited layers.
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2022, Vol. 36 
