Direct Energy Deposition of Inconel 718 onto Cu Substrate for Bimetallic Structures with Excellent Comprehensive Properties

In the aerospace sector, integrating advanced materials with high mechanical capabilities represents the forefront of material science, especially in the field of rocketry. Bimetallic structures are increasingly used in aerospace applications due to their combination of high strength-to-weight ratio, thermal conductivity, and corrosion resistance. Among these, Inconel-copper (In718-Cu) systems are particularly promising, although large differences in thermophysical and mechanical properties between the two materials can induce residual stresses, cracks, and other interfacial defects, requiring careful process control. This study evaluates the fabrication of In718-Cu structures through Direct Energy Deposition (DED), in which In718 was deposited onto a copper substrate using an innovative deposition strategy. Interface quality and microstructure were characterized by SEM/EDS and X-ray diffraction, whereas the mechanical properties were evaluated by nanoindentation, indentation creep, and tensile testing. The results showed that crack-free samples can be achieved, with strong diffusion bonding at the interface and efficient precipitation strengthening on the copper side already in the as-built condition. A uniform distribution of precipitates and consistent penetration depth were also observed, confirming the effectiveness of the deposition strategy for producing reliable In718-Cu components.