Microwave absorption in radar stealth technology is faced with challenges in terms of its effectiveness in low-frequency regions. Herein, we report a new laser-based method for producing an ultrawideband metamaterial-based microwave absorber with a highly uniform sheet resistance and negative magnetic permeability at resonant frequencies, which results in a wide bandwidth in the L- to S-band. Control of the electrical sheet resistance uniformity has been achieved with less than 5% deviation at 400 Ω sq⁻¹ and 6% deviation at 120 Ω sq⁻¹, resulting in a microwave absorption coefficient between 97.2% and 97.7% within a 1.56–18.3 GHz bandwidth for incident angles of 0°–40°, and there is no need for providing energy or an electrical power source during the operation. Porous N- and S-doped turbostratic graphene 2D patterns with embedded magnetic nanoparticles were produced simultaneously on a polyethylene terephthalate substrate via laser direct writing. The proposed low-frequency, wideband, wide-incident-angle, and high-electromagnetic-absorption microwave absorber can potentially be used in aviation, electromagnetic interference (EMI) suppression, and 5G applications.

Tungsten (W) and stainless steel (SS) are well known for the high melting point and good corrosion resistance respectively. Bimetallic W–SS structures would offer potential applications in extreme environments. In this study, a SS→W→SS sandwich structure is fabricated via a special laser powder bed fusion (LPBF) method based on an ultrasonic-assisted powder deposition mechanism. Material characterization of the SS→W interface and W→SS interface was conducted, including microstructure, element distribution, phase distribution, and nano-hardness. A coupled modelling method, combining computational fluid dynamics modelling with discrete element method, simulated the melt pool dynamics and solidification at the material interfaces. The study shows that the interface bonding of SS→W (SS printed on W) is the combined effect of solid-state diffusion with different elemental diffusion rates and grain boundary diffusion. The keyhole mode of the melt pool at the W→SS (W printed on SS) interface makes the pre-printed SS layers repeatedly remelted, causing the liquid W to flow into the sub-surface of the pre-printed SS through the keyhole cavities realizing the bonding of the W→SS interface. The above interfacial bonding behaviours are significantly different from the previously reported bonding mechanism based on the melt pool convection during multiple material LPBF. The abnormal material interfacial bonding behaviours are reported for the first time.

Additive manufacturing (AM) is an emerging customized three-dimensional (3D) functional product fabrication technology. It provides a higher degree of design freedom, reduces manufacturing steps, cost and production cycles. However, existing metallic component 3D printing techniques are mainly for the manufacture of single material components. With the increasing commercial applications of AM technologies, the need for 3D printing of more than one type of dissimilar materials in a single component increases. Therefore, investigations on multi-material AM (MMAM) emerge over the past decade. Lasers are currently widely used for the AM of metallic components where high temperatures are involved. Here we report the progress and trend in laser-based macro- and micro-scale AM of multiple metallic components. The methods covered in this paper include laser powder bed fusion, laser powder directed energy deposition, and laser-induced forward transfer for MMAM applications. The principles and process/material characteristics are described. Potential applications and challenges are discussed. Finally, future research directions and prospects are proposed.