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<p>The focus of this work is to determine an optimum groove geometry for repairing damaged IN625 components effectively using the laser directed energy deposition (LDED) process. To this end, a repair geometry optimization study was performed, in which nine different groove shapes, including Square, U-groove, Semi-circular, Trapezoidal, Trapezoidal with filleted corner, V groove−90°, V groove−120°, V groove−45°, and V groove−60°, were repaired using optimized process parameters (laser power = 400 W, scanning speed = 960&#xa0;mm/min, powder feed rate = 3.5&#xa0;g/min). The laser source used for the deposition was a Nd: YAG continuous-wave laser with a 0.6&#xa0;mm spot size. Among the different groove shapes, the V groove−120° demonstrated successful repair with strong metallurgical bonding with the substrate owing to better laser exposure. The repaired part revealed columnar grains with a dendritic substructure, which were replaced by recrystallized equiaxed grains after solution treatment. The repaired region showed a preferential texture along &lt; 100 &gt; due to the directional solidification of the LDED process, whereas the substrate region demonstrated a random texture. The repair quality was assessed through mechanical testing of the repaired samples and a comparison with the wrought equivalent (with and without solution treatment). The repaired part exhibited a hardness of 301 ± 11&#xa0;HV, which is higher than that of the substrate (254 ± 7&#xa0;HV). The ultimate tensile strength of the repaired part and the substrate were 942 ± 12&#xa0;MPa and 960 ± 9&#xa0;MPa, respectively, suggesting equivalent tensile properties of the repaired part and wrought substrate. This indicates the potential of LDED to perform high-quality repairs. The solution treatment of the repaired sample resulted in decreased strength but improved elongation owing to grain coarsening and dissolution of the hard Laves phase.</p>

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Optimization of Groove Geometry for Repair of Inconel 625 Components by Laser Directed Energy Deposition

  • 期刊论文

  • 发表日期：

    2026年7月31日

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  • Amit K. Praharaj,
  • P. B. Malathesh,
  • Raja S. Thanumoorthy,
  • Jitender K. Chaurasia,
  • Ravi C. Gurugubelli,
  • Anil K. Vesangi,
  • P. S. Suvin,
  • Vamsi K. Balla,
  • Srikanth Bontha

摘要

The focus of this work is to determine an optimum groove geometry for repairing damaged IN625 components effectively using the laser directed energy deposition (LDED) process. To this end, a repair geometry optimization study was performed, in which nine different groove shapes, including Square, U-groove, Semi-circular, Trapezoidal, Trapezoidal with filleted corner, V groove−90°, V groove−120°, V groove−45°, and V groove−60°, were repaired using optimized process parameters (laser power = 400 W, scanning speed = 960 mm/min, powder feed rate = 3.5 g/min). The laser source used for the deposition was a Nd: YAG continuous-wave laser with a 0.6 mm spot size. Among the different groove shapes, the V groove−120° demonstrated successful repair with strong metallurgical bonding with the substrate owing to better laser exposure. The repaired part revealed columnar grains with a dendritic substructure, which were replaced by recrystallized equiaxed grains after solution treatment. The repaired region showed a preferential texture along < 100 > due to the directional solidification of the LDED process, whereas the substrate region demonstrated a random texture. The repair quality was assessed through mechanical testing of the repaired samples and a comparison with the wrought equivalent (with and without solution treatment). The repaired part exhibited a hardness of 301 ± 11 HV, which is higher than that of the substrate (254 ± 7 HV). The ultimate tensile strength of the repaired part and the substrate were 942 ± 12 MPa and 960 ± 9 MPa, respectively, suggesting equivalent tensile properties of the repaired part and wrought substrate. This indicates the potential of LDED to perform high-quality repairs. The solution treatment of the repaired sample resulted in decreased strength but improved elongation owing to grain coarsening and dissolution of the hard Laves phase.