Metallverarbeitung und Rohprodukte aus Metall
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Traditionally, repairing coated substrates requires completely removing damaged, wear-resistant layers before recoating. This process leads to high costs, extended downtime, and material waste. Flexible brazing tapes, which are composed of alloy powder and an organic binder, offer an alternative to full coating removal for targeted repairs. Despite this, the process of vacuum brazing these tapes may lead to the formation of defects, including pores caused by trapped gases or residual binder, which compromise coating durability and corrosion resistance. This study focuses on the utilization of laser remelting as a method for post-processing nickel- and iron-based mixed alloy brazing tapes, with the aim of improving the integrity of the coating. Surface quality was assessed via microscopy and microhardness testing by systematically varying laser power, scanning speed, and hatch distance. Among the parameters studied, the most suitable laser parameter combination was found to be 350 W laser power, 250 mm/s scanning speed, and a hatch distance of 0.02 mm. These parameters yielded crack- and pore-free coatings with a remelting depth of 160.3 ± 17.2 µm and a microhardness of 701 ± 23 HV1, which is an 85% increase over as-brazed samples. Wear testing revealed a reduced coefficient of friction, and electrochemical corrosion tests showed lower corrosion current density and enhanced repassivation behavior in remelted coatings. These improvements demonstrate that laser remelting significantly enhances the microstructure, hardness, wear resistance, and corrosion performance of brazed coatings, providing an effective method for localized repair while minimizing material consumption and processing duration.
Directed Energy Deposition-Laser (DED-L) enables high-performance coatings through melting and successive powder deposition. Its compositional flexibility suits functionally graded layers that enhance corrosion and wear resistance. This study aimed to improve parameters for producing dense, defect-free, graded Ni- and Fe-based coatings by varying the scanning speed and deposition strategy (monodirectional versus bidirectional, with/without layer rotation), while keeping the power and hatch distance constant. Laser and electron microscopy were used to link parameters to porosity and uniformity. Optimal settings minimized pores, improved interlayer bonding and preserved geometry; inadequate parameters yielded porous, irregular deposits. A bidirectional path with 90° rotation appeared best. Ongoing research activities are needed to assess its properties.
Highlights
What are the main findings?
- Bidirectional samples show fewer pores than samples with monodirectional movement.
- Increasing the scanning speed leads to lower porosity (bidirectional scanning mode with 90°
layer rotation).
- Bidirectional deposition with 90° layer rotation exhibits best quality
What are the implications of the main findings?
- Systematic study of scanning speed and deposition strategy.
- Practical guidance for process improvement of graded metal coatings; properties under evaluation.
- Functionally graded Ni-Fe coatings fabricated by DED-L with tailored microstructures.
Directed energy deposition–electron beam (DED-EB) additive manufacturing is a highly promising process for the fabrication of titanium components, offering high deposition rates and precise process control under vacuum conditions. However, optimizing the deposition characteristics, such as dimensional accuracy, surface quality, and layer uniformity, remains a key challenge, partly due to the complex dynamics of heat input and melt pool behavior. This study examines the influence of electron beam modulation on these deposition characteristics by systematically varying beam deflection parameters, including frequency and pattern, during the wire-based additive manufacturing of titanium. The effects of beam modulation on wire melting, melt pool stability, layer formation, and overall build geometry were thoroughly evaluated. The results demonstrate that carefully controlled electron beam modulation enables significant improvements in deposition stability, surface finish, and control over geometric features, thereby enhancing process reliability and enabling the production of near-net-shape titanium components. Notably, a parameter set consisting of a circular beam deflection at an oscillation frequency of 500Hz and an overfocus setting of + 40 mA effectively minimized surface ripples and waviness, thereby enhancing process stability and yielding defect-free components. These insights contribute to advancing DED-EB as a viable solution for applications where high geometric accuracy and process efficiency are demanded.

