# CAREER: Process-Induced Interfacial Crack Formation in Multi-Metal Additive Manufacturing

> **NSF 01002627DB NSF RESEARCH & RELATED ACTIVIT** · Arizona State University (AZ) · $549,994

## Abstract

Multi-metal additive manufacturing enables the creation of multi-metal architectures that exceed the intrinsic property limits of single alloys by spatially combining complementary materials within a single component. Such capability is critical for next-generation aerospace systems, energy technologies, biomedical devices, and national defense applications. Despite its promise, the widespread use of multi-metal additive manufacturing is limited by cracking at dissimilar-metal interfaces, which undermines reliability and discourages industrial adoption. This Faculty Early Career Development Program (CAREER) project addresses this fundamental challenge by developing a science-based understanding of how and why interfacial cracks form during processing and how they can be avoided. By enabling defect-free multi-metal components, the project supports U.S. competitiveness in advanced manufacturing while contributing to workforce development. Integrated research, education, and outreach activities engage K–12 students, undergraduates, and graduate researchers through hands-on design-to-manufacture challenges and a new forensic learning framework that emphasizes evidence-based reasoning, creativity, and critical thinking.

The research objective is to develop a rigorously validated multi-physics framework that predicts process-induced interfacial cracking in multi-metal additive manufacturing. The project integrates multicomponent heat and mass transport, grain-scale crystal plasticity, and coupled fracture mechanics to capture the interactions among residual stress evolution, liquid-metal embrittlement with Kirkendall porosity, and brittle intermetallic layer formation. Two representative alloy systems, Cu-10Sn/904L stainless steel and Ti-6Al-4V/AlSi10Mg, are studied to isolate distinct cracking mechanisms and validate the framework across different metallurgical regimes. Model predictions are validated using in-operando synchrotron X-ray imaging and diffraction and hig

## Key facts

- **NSF award ID:** 2541585
- **Awardee organization:** Arizona State University (AZ)
- **SAM.gov UEI:** NTLHJXM55KZ6
- **PI:** Zhengtao Gan
- **Primary program:** 01002627DB NSF RESEARCH & RELATED ACTIVIT
- **All programs:** CAREER-Faculty Erly Career Dev, MATERIALS PROCESSING AND MANFG, Materials Engineering, Advanced Manufacturing, UNDERGRADUATE EDUCATION, GRADUATE INVOLVEMENT, MANUFACTURING
- **Estimated total:** $549,994
- **Funds obligated:** $549,994
- **Transaction type:** Standard Grant
- **Period:** 08/01/2026 → 07/31/2031

## Primary source

NSF Award Search: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2541585

## Citation

> US National Science Foundation, Award 2541585, CAREER: Process-Induced Interfacial Crack Formation in Multi-Metal Additive Manufacturing. Retrieved via AI Analytics 2026-07-05 from https://api.ai-analytics.org/grant/nsf/2541585. Licensed CC0.

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