Laser‐Based Directed Energy Deposition Remanufacturing of Gray Cast Iron using Stainless Steel 316L and Inconel 625 Filler Materials

Abstract

Directed energy deposition (DED) is identified as an ideal candidate for restoring damaged or worn cast iron components such as agricultural engine blocks, housings, and manifolds. While this laser‐based process offers superior control of the heat input compared to traditional arc‐based repair, gaseous porosity and brittle intermetallic structures reduce the strength and ductility of the fusion zone. Varying combinations of Fe–Ni–Cr alloys have found success in remanufacturing cast iron using laser‐based DED, but little attention has been given to the consequence of filler material composition and form, that is, wire versus powder. This study quantifies structural characteristics in cast iron repairs and offers microstructural and process‐specific insights to support these observations. With appropriate thermal conditions, up to 98.7% of the original tensile strength of gray cast iron may be achieved. These results point toward superior gray cast iron restoration using tunable laser‐based DED.