Fabricating an Inconel 718 superalloy using electromagnetic stirring assisted laser solid forming (EMS-LSF) is a novel method to modify its microstructure and mechanical properties by consuming the Nb element in the γ phase to alleviate interdendritic segregation. The precipitate of the δ phase at 950 °C after EMS-LSF can help to achieve the uniform diffusion of Nb, and can also improve its mechanical properties. The precipitation behavior of the δ phase in an EMS-LSF Inconel 718 superalloy with different heat treatment processes has been investigated. The results show that the morphology of the δ phase changes from rod-like to a long-needle shape and tends to grow from the inter dendrite to the core dendrite with electromagnetic field intensity increasing, which is accompanied by the “cutting” and “dissolution” of the Laves phase. Through precipitation kinetics analysis, the precipitation rate of the δ phase is seen to increase with the electromagnetic field intensity increasing. Under a combination of electromagnetic stirring and laser solid forming, the microhardness of the Inconel 718 samples increased slightly due to the fact that a higher content of Nb was distributed in the core dendrite resulting from the serious convection of liquid metal, which can strengthen the matrix.

Laser forming repair (LFR) technology has considerable potential in high strength steel structure repair. 34CrNiMo6 steel has been widely used in high-value components, and it is imperative to repair these damaged components. In this study, two different thicknesses of repaired layers are deposited on the 34CrNiMo6 wrought substrate with five layers and 20 layers via LFR technology. The microstructure, phases, microhardness, and tribological properties are analyzed using optical microscopy, scanning electron microscopy, X-ray diffraction, Vickers hardness testing, and dry sliding wear testing. These results show that the 34CrNiMo6 repaired layers were successfully deposited on the substrate. The microstructure of the laser-repaired layers in the five-layer sample included bainite and retained austenite. For the 20-layer sample, the microstructure in the top of the repaired layers was still bainite and retained austenite, whereas that in the bottom of the repaired layers was transformed into ferrite and cementite. The average coefficients of friction of repaired layers is not significantly different from the substrate. The wear rate of the five LFR layers, 20-layer LFR, and substrate samples were 12.89 × 10⁻⁶, 15 × 10⁻⁶, and 23.87 × 10⁻⁶ mm³/N·m, respectively. The laser forming repaired samples had better wear resistance compared to the substrate. The wear mechanism of laser forming repaired samples is abrasive wear; whereas that of the substrate is abrasive wear and fatigue wear.

Alloy sheets of type 2060 aluminum–lithium were welded by laser beam welding (LBW) filled with ER2319 Al-5.6Cu wire. Microstructural observations showed the uneven distribution of columnar grains, equiaxed grains and equiaxed dendrite grains in the weld. The θ′(Al₂Cu) phase and other phases precipitated in the weld. The θ′(Al₂Cu) phase centrally distributed at the grain boundaries. During the immersion corrosion, the pitting corrosion first occurred and then gradually expanded and transformed to intergranular corrosion and exfoliation corrosion. The electrochemical corrosion test showed a higher corrosion tendency of the base metal and heat-affected zone for the lower corrosion potential, but the corrosion current density of the weld was relatively larger. The segregation of Cu, Mg and other elements at the grain boundary aggravated the occurrence of intergranular corrosion.

In the process of laser-based direct energy deposition, the particle concentration distribution and geometric characteristics of powder flow play an important role in laser–powder interaction and powder utilization, and they affect the forming quality and accuracy. In the current study, based on the geometry information of a powder nozzle and the divergence angles of a powder jet at the nozzle outlet, the geometric profile of a powder stream is analyzed. A set of formulas for calculating the geometric characteristics of the powder stream is derived based on an analytic geometry method. The influence of each parameter on the geometric characteristics of the powder stream is further studied using single-factor and sensitivity analyses. Validation is performed by comparing the results from the presented analytical expressions with those from experiments and/or simulations in published papers. The analytical formulas provided in this paper are simple and practical, providing a theoretical foundation for the control of powder flow and related processes in the forming process.

Repairing damaged parts using proper repairing methods has become an important means to reduce manufacturing and operational costs and prolong the service life of 34CrNiMo6 steel structures. In the conventional fusion repairing method, welding wire and powder are often used as filling materials. Filling materials are often expensive or difficult to find. Some metallurgical issues (such as solidification crack, higher distortion) were also found with these methods. At the same time, most of the equipment that requires welding wire and powder is expensive. In this study, a new method based on friction stir processing (FSP) was successfully employed to repair 34CrNiMo6 steel, using a block as filling material. Filling blocks are much cheaper than conventional fusion repair consumables. As a result of solid-state repair, this method can also avoid the metallurgical issues of fusion repair. The microstructure and mechanical properties of the repaired samples were investigated using OM (Optical Microscope), SEM, EDS (Energy Dispersive Spectroscopy), XRD, and a Vickers hardness electronic universal tensile tester. The results showed that 34CrNiMo6 steel was successfully repaired by this method, with no defect. Tensile tests showed that the maximum ultimate strength (UTS) was 900 MPa and could reach 91.8% of that of the substrate. The fracture mode of the tensile samples was ductile/brittle mixed fracture. Hence, the repairing method based on FSP appears to be a promising method for repairing castings.

A double reinforced layer on an aluminum alloy surface was produced using friction stir processing (FSP) by adding 34CrNiMo6 powder into Al (AA2024) substrate for better wear resistance and gradient transitions. The microstructures of the composites were analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The phase composition was examined by X-ray diffraction (XRD). The results show that the double reinforced layer of the Al₁₃Fe₄ intermetallic compound could be successfully fabricated via FSP. The volume fraction of Al₁₃Fe₄ in the double reinforced layer was higher than in the single reinforced layer due to adding 34CrNiMo6 powder and reinforced twice, and the Al₁₃Fe₄ particles were dispersed more homogeneously in the double reinforced layer. The interfaces between the double and single reinforced layer had a good metallurgical bond. The microhardness of the double reinforcement layer was significantly increased. Compared with the AA2024 substrate, the microhardness of the double and single reinforced layers increased five- (576 HV) and two-fold (254 HV), respectively.