Abstract
Laser directed energy deposition (L-DED) is an advanced manufacturing technology utilized for the production, surface cladding, and repair of metallic components. While a growing list of alloys have been processed in this context, limited research has addressed its application to Ni-Cu alloys such as Monel 400 (Ni-32Cu). This alloy is of significant commercial interest in many domains due to its excellent corrosion resistance. As such, it is frequently applied as a conventionally welded overlay on steel to mitigate its corrosion in marine environments. This approach generates considerable heat input that necessitates the application of a buffer layer such as IN625 or ERNi-1 to ensure that dilution of the subsequently applied monel 400 is minimized and corrosion resistance retained. L-DED offers a promising alternative, as its lower energy input can minimize dilution and potentially eliminate the need for a buffer layer reducing costs and enhancing productivity. The objective of this research was to assess the feasibility of this concept by depositing gas atomized Monel 400 powder on HY-80 steel via L-DED. Effective sets of deposition parameters were determined by systematic adjustments to settings for laser power, scan speed, hatch spacing, and powder feed rate while producing single-track deposits and single-layer clads. All deposits were analyzed through a combination of laser confocal microscopy, SEM/EDS, and micro-hardness testing. These results provided valuable insight on to the extent of dissolution, presence of defects, and size of the heat-affected zone.