Experimental studies on process-induced morphological characteristics of macro- and microstructures in laser consolidated alloys

Laser consolidation (LC) developed by National Research Council’s Industrial Materials Institute (NRC-IMI-London) since mid-1990s, is a laser cladding based rapid manufacturing and material additive process that could fabricate a “net-shape” functional metallic shape through a “layer-upon-layer” deposition directly from a computer aided design model without using molds or dies. In order to evaluate the LC processability of different materials, some representative nickel-based superalloys (IN-625, IN-718, IN-738, and Waspaloy), stainless steels (austenitic SS316L and martensitic SS420), and lightweight alloys (Ti–6Al–4V titanium alloy and Al-4047 aluminum alloy) have been investigated. Like other laser cladding based processes, due to process-induced rapid directional solidification, the LC alloys have demonstrated certain unique morphological characteristics. Moreover, the “as-consolidated” LC alloys, in nature, are in the “as-quenched” state, and some precipitation processes from their matrices, which are sometimes critical to the development of mechanical performance of the materials, could be effectively suppressed or retarded. Post-heat treatments, therefore, could necessarily facilitate the process of achieving their required operational microstructures. In this article, a comprehensive investigation was performed including metallurgical soundness and process-induced morphological characteristics of the LC materials, and microstructure development brought by post-LC heat treatments using optical microscope, scanning electron microscope, and X-ray diffraction. The implications on the mechanical performance of the LC materials were discussed as well in order to provide essential information for potential industrial applications of the LC materials.