This paper aims at an in-depth and comprehensive analysis of mechanical and microstructural properties of AISI 316L austenitic stainless steel (W. Nr. 1.4404, CL20ES) produced by laser powder bed fusion (LPBF) additive manufacturing (AM) technology. The experiment in its first part includes an extensive study of the anisotropy of mechanical and microstructural properties in relation to the built orientation and the direction of loading, which showed significant differences in tensile properties among samples. The second part of the experiment is devoted to the influence of the process parameter focus level (FL) on mechanical properties, where a 48% increase in notched toughness was recorded when the level of laser focus was identical to the level of melting. The FL parameter is not normally considered a process parameter; however, it can be intentionally changed in the service settings of the machine or by incorrect machine repair and maintenance. Evaluation of mechanical and microstructural properties was performed using the tensile test, Charpy impact test, Brinell hardness measurement, microhardness matrix measurement, porosity analysis, scanning electron microscopy (SEM), and optical microscopy. Across the whole spectrum of samples, performed analysis confirmed the high quality of LPBF additive manufactured material, which can be compared with conventionally produced material. A very low level of porosity in the range of 0.036 to 0.103% was found. Microstructural investigation of solution annealed (1070 °C) tensile test samples showed an outstanding tendency to recrystallization, grain polygonization, annealing twins formation, and even distribution of carbides in solid solution.

While the machining of Inconel 718 has been widely studied, its cast counterpart Inconel 713LC remains underexplored, despite its relevance in high-temperature aerospace and energy components. This work presents a comprehensive investigation of dry milling behavior in Inconel 713LC, focusing on the interplay between tool wear, cutting forces, surface integrity, and chip formation across a broad range of cutting parameters. A stable process window was identified: 30–50 m/min cutting speed and 0.045–0.07 mm/tooth feed, where surface roughness remained below Ra 0.6 µm and tool life exceeded 10 min. Outside this window, rapid thermal and mechanical degradation occurred, leading to flank wear beyond the 550 µm limit and unstable chip morphology. The observed trends align with those in Inconel 718, allowing the cautious transfer of established strategies to cast alloys. By quantifying key process–performance relationships and validating predictive models for tool life and cutting forces, this study provides a foundation for optimizing the dry machining of cast superalloys. The results advance sustainable manufacturing practices by reducing reliance on cutting fluids while maintaining surface and dimensional integrity in demanding applications.

High-velocity oxyfuel (HVOF) coatings are used to protect components from corrosion and wear at higher temperatures and from wearing out after a certain period of time. Hence, to enhance the life of components, further recoating is required, but removing the older coating is a challenging task due to its high hardness. Thus, this research work studied the electrolytic dissolution process of removing WC-CoCr 86/10/4 HVOF coatings and found that at a voltage of 3 V, the coating was not removed, but at a slightly higher voltage of 6 V, the coating was removed completely. When the voltage was 12 V, the surface was damaged, and corrosion also occurred. A combination of tartaric acid (C₄H₆O₆), sodium bicarbonate (NaHCO₃), and water was used as an electrolyte. By using a combination of a voltage of 4.5 V, a current of 1.6 A, and an electrode distance of 55 mm, the coating was completely removed after 10 h, with negligible attacks on the base material. Where the corrosion of the base material is unacceptable, voltages in the range of 4 to 6 V are recommended. If parts have coatings on all surfaces, a voltage within the range of 6 to 12 V can be recommended. The coating from tab SB-002JI-5 TOOLOX-11 and hexagonal mandrel SB-00EA-1 160 TIS was also removed successfully.

The article deals with testing of the resistance against Foreign Object Damage (FOD) on leading edges of blisks (blade disks) in turboprop engines made of Ti6Al4V alloy. Such damage can occur during operation, when rapidly rotating compressor ...