The laser engineered net shaping (LENS®) process is shown here as an alternative to melting, casting, and powder metallurgy for manufacturing iron aluminides. This technique was found to allow for the production of FeAl and Fe₃Al phases from mixtures of elemental iron and aluminum powders. The in situ synthesis reduces the manufacturing cost and enhances the manufacturing efficiency due to the control of the chemical and phase composition of the deposited layers. The research was carried out on samples with different chemical compositions that were deposited on the intermetallic substrates that were produced by powder metallurgy. The obtained samples with the desired phase composition illustrated that LENS® technology can be successfully applied to alloys synthesis.

The influences of the processing parameters on the Mg₂FeH₆ synthesis yield were studied. Mixtures of magnesium hydride (MgH₂) and iron (Fe) were mechanically milled in a planetary ball mill under argon for 0.5-, 1-, 2- and 3-h periods and subsequently sintered at temperatures from 300–500 ${}^{\circ }$ C under hydrogen. The reaction yield, phase content and hydrogen storage properties of the received materials were investigated. The morphologies of the powders after synthesis were studied by SEM. The synthesis effectiveness map was presented. The obtained results prove that synthesis parameters, such as the milling time and synthesis temperature, greatly influence the reaction yield and material properties and show that extended mechanical milling may not be beneficial to the reaction efficiency.

Samples of 316L SS were manufactured by Laser Engineered Net Shaping (LENS^®) using different technological parameters. The deposited samples were investigated in terms of microstructure, mechanical properties, phase content and corrosion resistance (salt chamber and electrochemical corrosion). Parameters were chosen to obtain a proper sample built for layer thicknesses of 0.2, 0.4 and 0.7 mm by changing the laser feed rate while keeping the powder feed rate constant. After a comprehensive analysis of the results, it was found that the manufacturing parameters slightly affected the resulting microstructure and also had a minor impact (almost undetectable considering the uncertainty of the measurement) on the mechanical properties of samples. Decreases in resistance to electrochemical pitting corrosion and environmental corrosion with an increased feed rate and a decrease in layer thickness and grain size were observed; however, all additively manufactured samples were found to be less prone to corrosion than the reference material. In the investigated processing window, no influence of deposition parameters on the phase content of the final product was found—all the samples were found to possess austenitic microstructure with almost no detectable ferrite.