Laser-based fabrication with Ti- and Ni-base superalloys

Laser-based technology of direct metal deposition has matured into an industrially well established technique for precise coating deposition and additive manufacturing. By means of dedicated nozzle systems, suitable process equipment as well as well customized manufacturing strategies, the fabrication of miniaturized, but even very large components becomes feasible. This includes the use of powder as well as wire for the added material. Fostered by high demands, e. g. in the field of stationary gas turbines or jet engines, the state of the art has to be extended especially in the direction of lightweight fabrication as well as increased temperature performance of processed materials. However, from a materials perspective, these materials are often difficult to handle by liquid phase processing. Due to their beneficial material properties needed to fulfill the high performance requirements from the industry, titanium and nickel based superalloys have recently attracted considerable attention. Processing these materials, which are often characterized by a high brittleness and small process windows, is rather challenging and thus requires a customized laser-based fabrication process. The present paper shows recent advances to bring these materials into real applications through laser-based processing. This not only includes modifications of the laser process and the equipment itself, but also the support by hybrid processing, e. g. induction as well as closed loop process control. The paper will also highlight the importance of indepth materials knowledge and process understanding for highest quality 3D direct laser deposition.