Investigation of laser consolidation for manufacturing functional net-shape components for potential rocket engine applications

Abstract

Laser consolidation is an emerging novel computer-aided manufacturing process that produces net-shape functional metallic parts layer by layer directly from a CAD model by using a laser beam to melt the injected powder and re-solidifying it on the substrate or previous layer. As an alternative to the conventional machining process, this novel manufacturing process builds net-shape functional parts or features on an existing part by adding instead of removing material.In this paper, laser consolidation of IN-625 and Ti-6Al-4V alloys has been investigated to build several generic shapes representing parts that may have potential rocket engine applications. Laser consolidation produces components with good surface finish, dimensional accuracy and mechanical properties, and demonstrates the potential for direct manufacturing of functional net-shape components and tooling. In addition, some preliminary results demonstrate that the laser consolidation, in combination with solid-state, net-shape powder metallurgy processing, may provide a unique manufacturing capability to make very complex components for the rocket engines.Laser consolidation is an emerging novel computer-aided manufacturing process that produces net-shape functional metallic parts layer by layer directly from a CAD model by using a laser beam to melt the injected powder and re-solidifying it on the substrate or previous layer. As an alternative to the conventional machining process, this novel manufacturing process builds net-shape functional parts or features on an existing part by adding instead of removing material.In this paper, laser consolidation of IN-625 and Ti-6Al-4V alloys has been investigated to build several generic shapes representing parts that may have potential rocket engine applications. Laser consolidation produces components with good surface finish, dimensional accuracy and mechanical properties, and demonstrates the potential for direct manufacturing of functional net-shape components and tooling. In addition, some preliminary results demonstrate that the laser consolidation, in combination with solid-state, net-shape powder metallurg...