Semi-Hybrid CO₂ Laser Metal Deposition Method with Inter Substrate Buffer Zone.

Area of Science:

• Materials Science and Engineering
• Additive Manufacturing
• Metallurgy

Background:

• Laser metal deposition (LMD) using wire or powder is crucial for additive manufacturing.
• Substrate element diffusion (e.g., carbon, iron) into deposited alloys is a significant challenge, especially with dissimilar materials.
• Existing wire and powder deposition methods face limitations in preventing substrate diffusion and enabling prototyping on diverse substrates.

Purpose of the Study:

• To introduce and evaluate a novel Semi-Hybrid Deposition Method (S-HDM) for laser metal deposition.
• To demonstrate the effectiveness of S-HDM in preventing carbon and iron diffusion from a low alloy steel substrate.
• To compare S-HDM with traditional wire and powder laser deposition methods for prototyping Inconel 625.

Main Methods:

• Developed and implemented the Semi-Hybrid Deposition Method (S-HDM) combining wire and powder additive materials.
• Utilized a CO2 laser for metal deposition of Inconel 625 onto a structural steel substrate.
• Conducted comparative analysis using metallographic examination via optical and electron microscopy.

Main Results:

• S-HDM successfully prevented carbon and iron diffusion from the low carbon steel substrate into the Inconel 625 deposit.
• Metallographic analysis revealed significant advantages of S-HDM over conventional wire and powder laser deposition techniques.
• The study confirmed the efficacy of a buffer layer in reducing substrate component diffusion.

Conclusions:

• The developed Semi-Hybrid Deposition Method (S-HDM) offers a superior approach for laser metal deposition, particularly for dissimilar material combinations.
• S-HDM demonstrates significant potential for advanced high alloy material prototyping on low alloy structural steel substrates.
• This method overcomes key limitations of traditional deposition techniques, enabling broader applications in additive manufacturing.