Ultrasonic additive manufacturing (UAM) is a solid-state manufacturing process for making complex components. However, fabrication of ferritic (body centered cubic) steels has been challenging for UAM due to its high hardness. This research successfully joined AISI 4130 steel sheets by using soft Ni (face centered cubic) interlayers. The localisation of plastic deformation in the Ni-interlayer leads to a significant reduction in voids. A post-process heat-treatment was designed using thermodynamic calculations to dissolve nickel into steel matrix. Energy dispersive X-ray spectroscopy measurements showed ∼10 µm Ni from the interlayer diffused into the steel side, confirming the feasibility of the approach. The shear tests show a higher shear strength in comparison to as-processed 4130 without interlayers and post processed using hot isostatic pressing (HIP).
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