While repair is mainly used to restore the original part geometry and properties, hybrid manufacturing aims to exploit the benefits of each respective manufacturing process regarding either processing itself or resulting part characteristics. Especially with the current implementation of additive manufacturing in the production of TiAl, turbine blades for both hybrid manufacturing and repair new opportunities are enabled. One main issue is the compatibility of the two or more material types involved, which either differ regarding composition or microstructure or both. In this study, a TNM^TM-alloy (Ti-Nb-Mo) was manufactured by different processes (casting, forging, laser additive manufacturing) and identically heat-treated at 1290 °C. Chemical compositions, especially aluminum and oxygen contents, were measured, and the resulting microstructures were analyzed with Scanning Electron Microscopy (SEM) and High-energy X-ray diffraction (HEXRD). The properties were determined by hardness measurements and high-temperature compression tests. The comparison led to an overall assessment of the theoretical compatibility. Experiments to combine several processes were performed to evaluate the practical feasibility. Despite obvious differences in the final phase distribution caused by deviations in the chemical composition, the measured properties of the samples did not differ significantly. The feasibility of combining direct energy deposition (DED) with either casting or laser powder bed fusion (LPBF) was demonstrated by the successful build of the dense, crack-free hybrid material.

Intermetallic γ-TiAl based alloys exhibit excellent high-temperature strength combined with low density. This makes them ideal candidates for replacing the twice as dense Ni base super-alloys, currently used in the medium temperature range (~700 °C) of industrial and aviation gas turbines. An important step towards the serial production of TiAl parts is the development of suitable hot-forming processes. Thermo-mechanical treatments often result in mechanical anisotropy due to the formation of crystallographic textures. However, with conventional texture analysis techniques, their formation can only be studied after processing. In this study, in situ high-energy X-ray diffraction measurements with synchrotron radiation were performed during hot-forming. Thus, it was possible to record the evolution of the phase constitution as well as the formation of crystallographic texture of different phases directly during processing. Several process temperatures (1100 °C to 1300 °C) and deformation rates were investigated. Based on these experiments, a process window can be recommended which results in the formation of an optimal reduced texture.