Abstract The present work analyses the effect of laser powder bed fusion (LPBF) remanufacturing of wrought Inconel 718 on the metallurgical and surface characteristics of the part. The remanufactured part experienced geometrical mismatch due to computer-aided design (CAD) misalignment with the substrate. As a result, a ~200 μm shift in a material deposition is observed, leading to a material deposition without support from the substrate on one edge. The microstructural analysis of the remanufactured part showed an interface between the wrought substrate and LPBF processed layers. The substrate showed an equiaxed grain structure. However, a strongly textured columnar grain structure was observed in the remanufactured region. The remanufactured Inconel 718 showed lower micro-hardness, inhibiting the precipitation of strengthening precipitates during the LPBF process. The surface characterization showed a higher surface roughness and anisotropy in material distribution for overhanging edges due to layer deformation and lack of support from the substrate. It was observed that due to geometry mismatch, the overhanging side experienced layer deformation, thus leading to the formation of large undulations on the surface. A higher area fraction of fused powder particles on the overhanging side shows ineffective heat transfer due to the region's lack of efficient support.
Read full abstract