The effect of using two different deposition systems on the microstructure and mechanical properties was studied in this paper. For this purpose, laser-engineered net shaping (LENS) and high-power CO₂ laser deposition processes were applied to fabricate Inconel 625 samples. The microstructure of the Inconel 625 produced by both additive techniques was characterized using light microscopy (LM), scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM). The mechanical properties were characterized by tensile tests and microhardness measurements. High-power laser application resulted in a strong build texture, while, at low powers, the {011} Goss component increased. Both types of deposited materials showed dendritic microstructures with Ti-, Mo-, and Nb-rich zones at the cell boundaries, where numerous precipitates (Nb₂C, NbC, titanium carbides, Nb₃Ni, and NbNiCr) were also observed. It was also noted that both variants were characterized by the same slope with a proportional length, but the Inconel 625 fabricated via LENS showed a higher average yield strength (YS; 524 MPa vs. 472 MPa) and ultimate tensile strength (UTS; 944 MPa vs. 868 MPa) and lower elongation (35% vs. 42%) than samples obtained with the high-power CO₂ laser deposition process.

The quaternary Mg–9Li–2Al–0.5Sc alloy (in wt%) was prepared from pure components. After homogenization, the alloy was subjected to severe plastic deformation by KoBo extrusion and cyclic forging leading to grain refinement in the range of 0.5–2 µm of hexagonal close-packed (HCP) α phase. Deformed alloys showed high ultimate tensile strength near 200 MPa and good elongation in the range 30–40% at room temperature (RT). Large elongations close to 200% were obtained during the tensile test at a temperature of 200 °C. Deformed samples showed the presence of multiple voids confirming grain boundary sliding mechanism of deformation. Twins on {10 $$\overline{1}$$1 ¯ 2} planes were identified using electron backscatter diffraction analysis, being in a good agreement with the earlier observation of Mg–Li and Mg–Sc alloys. Intermetallic phases such as cubic MgSc were identified in deformed alloys mostly within HCP α phase, whereas HCP MgSc₂ particles were observed within body-centered cubic (BCC) β phase. Intermetallic phases were responsible for RT strengthening of alloys and slightly lower tensile elongation during superplastic deformation. Formation of the HCP α phase was observed within the BCC β phase in tensile deformed alloys. Atomic-level nucleation of HCP phase within the β phase was identified by the use of high-resolution transmission electron microscopy technique.

This article presents the results of the metal deposition process using additive materials in the form of filler wire and metal powder. An important problem in wire deposition using a CO₂ laser was overcome by using a combination of the abovementioned methods. The deposition of a multicomponent alloy—Inconel 625—on a basic substrate such as structural steel is presented. The authors propose a new approach for stopping carbon and iron diffusion from the substrate, by using the Semi-Hybrid Deposition Method (S-HDM) developed by team members. The proposed semi-hybrid method was compared with alternative wire and powder deposition using laser beam. Differences of S-HDM and classic wire deposition and powder deposition methods are presented using metallographic analysis, within optic and electron microscopy. Significant differences in the obtained results reveal advantages of the developed method compared to traditional deposition methods. A comparison of the aforementioned methods performed using nickel based super alloy Inconel 625 deposited on low carbon steel substrate is presented. An alternative prototyping approach for an advanced high alloy materials deposition using CO₂ laser, without the requirement of using the same substrate was presented in this article. This study confirmed the established assumption of reducing selected components diffusion from a substrate via buffer layer. Results of metallographic analysis confirm the advantages and application potential of using the new semi-hybrid method for prototyping high alloy materials on low alloy structural steel substrate.