Direct laser deposition (DLD), implemented on the basis of a 5-axis robot manipulator, is a very flexible technique with many adjustable process parameters affecting the quality of the final product. Objects manufactured by the DLD method may contain defects significantly reducing mechanical and functional properties. This article provides an overview of possible DLD process-induced defects that were identified by increasing the density of the produced material. The following defects were identified and discussed in the current work: Lack of fusion, porosity, cracking, oxide inclusions, and metal influx. It is shown that by changing such process parameters as laser power, powder feed rate, head lift and hatch distance, it is possible to improve the quality of the cladding and substantially reduce the process-induced defects.

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Additive manufacturing offers a unique way of anisotropic microstructure control with a high degree of design freedom. This study demonstrates that application of suitable process parameters and laser sources in selective laser melting may favour either one sharp single component texture, more uniformly distributed crystal orientation, or a combination of the above in a preferred gradient, which influence the mechanical properties. It is shown that transitions in microstructure, texture, and properties in fabricated Inconel 718 functionally graded components can be obtained at relatively small or large length scales, depending upon the functional gradient desired in a particular application. Results obtained by electron backscatter diffraction showed distinct regions of coarse elongated grains with a strong (001) orientation uniformly embedded in randomly distributed fine grained matrix. Mechanical tests in the form of hardness, tensile and in-situ digital image correlation tests showed steep transitions in the developed Inconel gradients. The observed mechanical properties were found to be primarily dependent on the grain size and texture and are superior to the cast samples for both laser sources. The developed process strategy can be further applied to design functional gradients with selected tailored properties and to account for directional anisotropy of solidified components.@en

Additive manufacturing (AM) technologies are known to allow the production of parts with an extreme degree of complexity, enabling design and functional part optimization. However, the resulting microstructures and mechanical properties of AM materials are not well understood due to unique and complex thermal cycles observed during processing. This study aims to adjust the microstructure of Inconel 718 specimens produced by selective laser melting (SLM). The microstructural design was achieved through process parameters manipulation and post-process heat treatment. The effects of heat treatment on microstructure, process induced defects, deformation behaviour and failure mechanisms were studied. Directional columnar grained microstructure accompanied by interdendritic Laves phases and carbide particles was observed in as-processed material. Hot isostatic pressing (HIP) improved mechanical properties, which was attributed to dissolution of undesirable Laves and δ-phase as well as pore closure. All investigated samples maintained their intended tailored microstructural build up with distinct differences in mechanical properties. The results presented in this study show the capability of the SLM process to produce parts with mechanical properties better than conventional Inconel material. The microstructural design demonstrated here can be exploited in AM fabrication of complex components requiring challenging high-temperature mechanical performance.

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