Laser-directed energy deposition (DED) offers significant potential for the additive manufacturing of thin-walled Inconel 718 aerospace components. However, the structural defects readily formed during deposition, along with the extensive precipitation of long-chain Laves phases between coarse dendrites, can severely compromise the mechanical properties of as-fabricated Inconel 718 parts. To address this, an ultrasonic-assisted DED (UDED) method was employed to reduce the deposited structural defects and refine crystalline structures, and the influences of ultrasonic energy fields on the microstructure and mechanical properties of thin-walled Inconel 718 samples were systematically investigated. The results demonstrated that ultrasonic vibration significantly enhances the microstructural quality by reducing porosity and pore size, weakening texture intensity, fragmenting long-chain Laves phases, mitigating severe elemental segregation, and refining matrix grains. Consequently, the UDED thin-walled Inconel 718 sample exhibited an approximately 15% increase in microhardness compared to the conventional DED counterpart, alongside satisfactory strength and ductility. This study highlights the superiority of UDED for microstructure tailoring and its potential for mechanical property regulations in thin-walled Inconel 718 aerospace components.

Ultrasonic-assisted laser-directed energy deposition (UA-DED) is a promising combined technology for manufacturing high-value thin-walled Inconel 718 components in aerospace. Nevertheless, the optimal ultrasonic frequency—a key parameter for achieving desirable performance in thin-walled Inconel 718 alloys—remains to be determined. In this study, we systematically investigated the influence of ultrasonic frequency (12–20 kHz) on the microstructure and mechanical properties of thin-walled Inconel 718 fabricated by UA-DED. The results revealed that an ultrasonic frequency of 20 kHz was optimal and can yield significant improvements in the microstructures of the as-deposited sample coordinate planes, manifested by the complete suppression of large pores, three-dimensional refinement of the γ matrix grains, alleviation of Nb and Mo segregation, the reduction of fragmented Laves particles, a decrease in residual macroscopic stresses, and homogeneous distributions of γ′/γ″ phases and γ-grain orientation. Meanwhile, the application of a 20 kHz ultrasonic frequency endows the manufactured thin-walled 718 parts with superior mechanical properties, including a tensile strength of 899 MPa in the laser scanning direction and 877 MPa in the build direction, along with the corresponding elongations of 34.8% and 38.9%. This work demonstrates the potential of modulating ultrasonic frequency to tailor microstructures and produce high-performance thin-walled Inconel 718 aerospace components.

The repair or remanufacturing technology has great economic potential in the advanced aerospace manufacturing field, especially for high-valued fragile turbine blades. Besides cost concerns, the techniques available and their reliability are of crucial importance in the aeroengine turbine blade reconstruction for engineers and researchers. This review summarizes the advantages and disadvantages of traditional welding-based repair methods, with a particular focus on the advanced manufacturing techniques including laser additive manufacturing and brazing. The materials potentially utilized in turbine blade repair, as well as the relevant microstructure characteristics and resulting mechanical properties, are also introduced and discussed. Finally, it looks forward to the application prospect of current technologies and the key challenges to develop more effective, efficient, and economical blade repair solutions.