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Bimetallic Al–Fe composites with tailored properties produced by cold spray additive manufacturing

Can two fundamentally different metals be engineered into a bimetallic structures with a tunable balance of strength and ductility?

We are pleased to share a new publication from our group, recently published in Materials & Design. The study, “Bimetallic Al–Fe Composites with Tailored Properties Produced by Cold Spray Additive Manufacturing,” examines how retained Fe content and its spatial distribution govern densification, deformation, mechanical performance, and fracture behaviour in cold-sprayed Al–Fe composites.

By establishing a direct link between composition, microstructure, and mechanical response, the work identifies an intermediate Fe range that delivers the most favourable balance between strengthening and ductility, while revealing how particle clustering and interface-controlled damage limit performance at higher Fe contents.

Congratulations to the authors Kiran Tulasagiri Raddi, Asghar Heydari Astaraee, Sara Bagherifard.