Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturing
Additive manufacturing (AM) demonstrates promising applications in component repair, yet its continuous processing mode unavoidably induces localized heat accumulation, leading to critical defects such as microstructural heterogeneity, harmful phase formation and residual stress. These issues collec...
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Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425016692 |
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| author | Yi Li Junbo Wu Maoyuan Li Weiwei Xu Ruifang Ye Zhenzhong Wang |
| author_facet | Yi Li Junbo Wu Maoyuan Li Weiwei Xu Ruifang Ye Zhenzhong Wang |
| author_sort | Yi Li |
| collection | DOAJ |
| description | Additive manufacturing (AM) demonstrates promising applications in component repair, yet its continuous processing mode unavoidably induces localized heat accumulation, leading to critical defects such as microstructural heterogeneity, harmful phase formation and residual stress. These issues collectively compromise the structural integrity and functional performance of repaired components. To address these limitations, this study proposes a hybrid additive-subtractive manufacturing (HASM) strategy integrating off-axis fine wire-laser directed energy deposition (OAFW-LDED) with periodic milling operations. By employing a self-developed dual five-axis hybrid machining system, we achieved precise layer-wise repair of Inconel 718 superalloy on 304 stainless steel shafts. The HASM process orchestrates multistage thermo-mechanical control through OAFW-LDED/milling cycles, achieving controlled material deposition and unique microstructural evolution via mitigated thermal accumulation, enhanced solidification rates, and localized remelting-recrystallization. This approach refined the average equivalent grain size from 85.7 ± 3.2 μm to 56.2 ± 1.8 μm (34 % reduction), alleviated thermal stresses, and suppressed Nb segregation at dendritic boundaries. Notably, it transformed continuous long-chained Laves phases into discrete blocky particles. The average peak hardness increased by 26 % (from 271 to 340 HV), and surface flatness increased by 300 % (from 473.5 to 157.7 μm). This work presents a scalable manufacturing framework for high-performance remanufacturing of critical shaft components, demonstrating the synergistic benefits of combining AM's geometric freedom with subtractive manufacturing's precision control. |
| format | Article |
| id | doaj-art-e87aec62013b46749276fd6296ee7093 |
| institution | DOAJ |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-e87aec62013b46749276fd6296ee70932025-08-20T02:40:15ZengElsevierJournal of Materials Research and Technology2238-78542025-07-01373289330210.1016/j.jmrt.2025.07.011Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturingYi Li0Junbo Wu1Maoyuan Li2Weiwei Xu3Ruifang Ye4Zhenzhong Wang5Sichuan Institute of Xiamen University, School of Aerospace Engineering, Xiamen University, Xiamen, 361005, ChinaSichuan Institute of Xiamen University, School of Aerospace Engineering, Xiamen University, Xiamen, 361005, ChinaSichuan Institute of Xiamen University, School of Aerospace Engineering, Xiamen University, Xiamen, 361005, ChinaSichuan Institute of Xiamen University, School of Aerospace Engineering, Xiamen University, Xiamen, 361005, ChinaFujian Key Laboratory of Green Intelligent Drive and Transmission for Mobile Machinery, Huaqiao University, Xiamen, 361021, China; Corresponding author.Sichuan Institute of Xiamen University, School of Aerospace Engineering, Xiamen University, Xiamen, 361005, China; Corresponding author.Additive manufacturing (AM) demonstrates promising applications in component repair, yet its continuous processing mode unavoidably induces localized heat accumulation, leading to critical defects such as microstructural heterogeneity, harmful phase formation and residual stress. These issues collectively compromise the structural integrity and functional performance of repaired components. To address these limitations, this study proposes a hybrid additive-subtractive manufacturing (HASM) strategy integrating off-axis fine wire-laser directed energy deposition (OAFW-LDED) with periodic milling operations. By employing a self-developed dual five-axis hybrid machining system, we achieved precise layer-wise repair of Inconel 718 superalloy on 304 stainless steel shafts. The HASM process orchestrates multistage thermo-mechanical control through OAFW-LDED/milling cycles, achieving controlled material deposition and unique microstructural evolution via mitigated thermal accumulation, enhanced solidification rates, and localized remelting-recrystallization. This approach refined the average equivalent grain size from 85.7 ± 3.2 μm to 56.2 ± 1.8 μm (34 % reduction), alleviated thermal stresses, and suppressed Nb segregation at dendritic boundaries. Notably, it transformed continuous long-chained Laves phases into discrete blocky particles. The average peak hardness increased by 26 % (from 271 to 340 HV), and surface flatness increased by 300 % (from 473.5 to 157.7 μm). This work presents a scalable manufacturing framework for high-performance remanufacturing of critical shaft components, demonstrating the synergistic benefits of combining AM's geometric freedom with subtractive manufacturing's precision control.http://www.sciencedirect.com/science/article/pii/S2238785425016692Wire-laser directed energy depositionHybrid additive-subtractive manufacturingLaves phaseMicrostructure and mechanical propertiesRemanufacturing |
| spellingShingle | Yi Li Junbo Wu Maoyuan Li Weiwei Xu Ruifang Ye Zhenzhong Wang Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturing Journal of Materials Research and Technology Wire-laser directed energy deposition Hybrid additive-subtractive manufacturing Laves phase Microstructure and mechanical properties Remanufacturing |
| title | Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturing |
| title_full | Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturing |
| title_fullStr | Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturing |
| title_full_unstemmed | Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturing |
| title_short | Improved Inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and Laves phase suppression in hybrid additive-subtractive manufacturing |
| title_sort | improved inconel 718 superalloy repaired performance on 304 stainless steel shafts via recrystallization and laves phase suppression in hybrid additive subtractive manufacturing |
| topic | Wire-laser directed energy deposition Hybrid additive-subtractive manufacturing Laves phase Microstructure and mechanical properties Remanufacturing |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425016692 |
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