Hybrid Method to Achieve Forged Microstructures and Properties in Laser Deposited Components

Laser deposition has been shown to produce high quality solidified material. The properties often times meets the minimum standards for wrought products, such as for Ti-6Al-4V. However, this material, despite being fairly high quality is still just a good casting.  It would be desirable to be able to produce a wrought structure through additive manufacturing techniques, particularly laser deposition.  A hybrid manufacturing method has been developed which utilizes laser deposition alternating with friction stir processing to build a wrought material without the use of dies. The friction stir zone can be tailored to replace the entire deposition bead and the subsequent laser deposits can be adjusted to not destroy the fine microstructure produced by the friction stir.  In this paper this hybrid manufacturing technique will be described and results given for microstructure and mechanical properties.  The utilization of this hybrid method will be discussed in terms of applications and the fabrication of parts.